Modular Manifold Block Assembly for Tool-Free Chiller Maintenance

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Solution Overview

Problem

Conventional refrigerated process chillers have high manufacturing and maintenance costs due to complex and space-intensive component stack-ups, which require specialized tools and labor for assembly and maintenance, making field upgrades difficult.

Innovation Solution

A modular manifold system with removably coupled manifold blocks that support sensing devices and components, allowing for tool-less assembly and disassembly, reducing the need for specialized tools and labor, and enabling easier field upgrades.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional copper tubing and fittings are used to assemble component stack up, then reliable fluid connections are achieved, but manufacturing costs and assembly complexity increase due to specialized welding/soldering requirements

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manifold system is divided into multiple removable manifold blocks that can be assembled in a modular fashion. Each block contains integrated fluid passages and mounting features, eliminating the need for complex welding/soldering of separate copper components while maintaining connection reliability through precision-machined interfaces and sealing mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functions are merged into single manifold blocks: fluid distribution, component mounting, and structural support are integrated into one unit. This consolidation eliminates the need for separate copper tubing, fittings, and sensors to be individually connected through welding/soldering, reducing manufacturing complexity while maintaining system reliability.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If conventional copper fittings and connectors are used, then sensing devices can be integrated into the process fluid flow path, but the component stack up occupies significant space within the chiller housing

Engineering Contradiction:

Improvesensing device integrationVSAvoidcomponent stack up space

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

Sensing devices and other components are mounted within the internal structure of the manifold blocks themselves. The manifold blocks contain recesses, bores, and mounting features that accommodate sensors, valves, and other components in a nested arrangement, minimizing the external footprint while maintaining full functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The manifold blocks utilize three-dimensional space efficiently by creating internal fluid passages and mounting locations in multiple dimensions. Components are arranged vertically and radially within each block rather than requiring linear expansion, reducing the overall volume occupied by the component stack up.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If permanent connections are used for sensing devices in component stack up, then reliable fluid-tight seals are achieved, but maintenance, repairs, and field upgrades become extremely difficult

Engineering Contradiction:

Improvefluid-tight sealVSAvoidmaintenance difficulty

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The manifold blocks feature dynamic, removable connections rather than permanent fixed joints. Quick-connect interfaces allow manifold blocks and sensing devices to be easily detached and reattached multiple times while maintaining fluid-tight seals, enabling simple maintenance and field upgrades without requiring specialized welding or disassembly tools.

Inventive Principle:

Principle #15Dynamics

4Reliability

If specialized tools and trained personnel are used for assembling component stack up, then proper installation and reliable connections are achieved, but manufacturing and in-use costs increase

Engineering Contradiction:

Improveinstallation qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manifold blocks are designed with self-aligning features, integrated sealing elements, and tool-free assembly mechanisms that allow standard personnel to install and maintain the system without specialized welding or brazing training. The design inherently guides proper assembly through mechanical features while maintaining installation quality.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20230314053A1Configurable Manifold System

Publication Date: 2023.10.05 THERMO FISHER SCIENTIFIC ASHEVILLE LLC

AI summary

A manifold system including a plurality of manifold blocks form a fluid conduit for fluid flow through the manifold system. The manifold blocks are removably coupled together. The manifold block includes a tubular body defining a first fluid passageway having a first flow axis. The first end includes a first female union defined by a first mounting flange and a neck extending from the first mounting flange in along the first flow axis toward the second end of the tubular body defining an opening to the first fluid passageway of the tubular body at the first end. The second end includes a male union defined by an annular flange and a tubular connector extending from the annular flange along the first flow axis to the second end of the tubular body defining an opening to the first fluid passageway at the second end.