Molded Field Flow Fractionator Assembly
Solution Overview
Problem
Field flow fractionation systems, particularly asymmetric flow field flow fractionators (AF4), are cumbersome to assemble and require extensive user intervention, making them less user-friendly and more expensive compared to competitive techniques like size exclusion chromatography (SEC), which limits their commercial success due to higher operational complexity and costs.
Innovation Solution
The design of a field flow fractionator with a top plate assembly, spacer, membrane, and bottom plate assembly that defines a separation channel, utilizing molded components and eliminating the need for adjustable fasteners and o-rings, allowing for mass production and simplification, similar to consumable SEC columns, with integrated sensors and memory for quality control and operational data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional field flow fractionator assembly methods are used with adjustable fasteners and o-rings, then the system allows for adjustment and assembly flexibility, but the assembly becomes cumbersome and requires extensive user intervention
Solution Approach 1:
The patent merges multiple separate components (fasteners, o-rings, sealing elements) into an integrated molded assembly. The channel assembly is formed as a single molded piece that incorporates the separation channel, frit support, and sealing features, eliminating the need for multiple discrete parts and their associated fastening hardware.
Solution Approach 2:
The patent employs molded channel assemblies that can be mass-produced as disposable or limited-life components. These molded assemblies replace expensive, complex adjustable mechanisms with simpler, pre-fabricated units that are optimized for ease of installation and replacement rather than long-term adjustment and reuse.
2Ease of manufacture
If traditional field flow fractionator designs are used, then the system provides separation functionality, but the operational complexity and costs increase compared to SEC systems
Solution Approach 1:
The patent adopts a disposable molded channel assembly approach similar to consumable SEC columns. The channel assemblies are manufactured as ready-to-use, non-adjustable units that can be mass-produced at low cost, replacing complex adjustable mechanisms with simple, pre-fabricated components that enhance commercial viability.
Solution Approach 2:
The patent replaces complex mechanical assembly mechanisms (adjustable fasteners, multiple o-rings, sealing compressions) with a simplified molded structure that achieves sealing and assembly through the molded geometry itself, reducing the need for additional mechanical components and assembly steps.
3Ease of operation
If adjustable fasteners and o-rings are used in field flow fractionators, then the system allows for assembly and disassembly, but user intervention and assembly time increase
Solution Approach 1:
The patent incorporates all necessary sealing and assembly features directly into the molded channel assembly during manufacturing. The frit support structure, sealing surfaces, and channel geometry are pre-formed in the molding process, eliminating the need for users to perform assembly adjustments or install separate sealing components.
Solution Approach 2:
The patent extracts and removes the adjustable fasteners and multiple o-rings from the assembly, retaining only the essential molded structure that provides both structural support and sealing functionality. This reduction in components directly reduces assembly time and user intervention requirements.
Data Source
AI summary
The present disclosure describes a field flow fractionator including (1) a top plate assembly including (a) a first non-corrosive material, and (b) at least three fluid fittings machined (simpler) into the material, (2) a spacer, (3) a membrane, (4) a bottom plate assembly including (a) a second non-corrosive material, (b) a cavity machined into the second non-corrosive material, (c) a frit configured to be placed into the cavity, and (d) at least one bottom plate o-ring configured to seal the bottom plate assembly to the spacer, and (5) where the top plate assembly, the spacer, the membrane, and the bottom assembly define a separation channel. In an embodiment, the at least three fluid fittings including a fitting for an in-flow, a fitting for an out-flow, and a fitting for a cross-flow.