Monolithic Fluidic Filter with Permeable Ridges for Mass Reduction
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Solution Overview
Problem
Existing fluidic filters for space propulsion face challenges such as high mass, wear, dislocation, thermal expansion mismatches, and increased pressure drop, while also being costly and prone to degradation in filtration rating over time.
Innovation Solution
A fluidic filter design featuring a filter housing with a multi-lobe cross-section and ridges that are permeable, integrated with the housing, formed monolithically using additive manufacturing, which reduces mass, prevents dislocation, and maintains a stable filtration rating by minimizing thermal expansion issues and clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etched disk filters are used to provide large filter area and fine filtration rates, then filtration performance is improved, but mass increases due to retained material
Solution Approach 1:
The filter element uses a porous structure where material is removed to create flow passages rather than retaining material. This reverses the conventional approach of etching through material, achieving filtration with reduced mass by allowing fluid passage through porous walls between disk rings
Solution Approach 2:
Instead of retaining material and removing small portions for filtration, the invention extracts material to create flow passages. The porous walls are formed by removing material strategically to allow fluid passage while maintaining structural integrity, thereby reducing overall mass
2Area of stationary object
If multiple components are used in etched disk filters, then filter area is increased, but component dislocation and wear occur
Solution Approach 1:
Multiple disk rings are joined together to form a single integrated filter element structure. The porous walls connect adjacent disk rings, creating a unified component that eliminates dislocation and wear issues between separate parts while maintaining large filter area
Solution Approach 2:
The filter element combines multiple disk rings with porous wall structures into a composite assembly. This integrated composite structure maintains the advantages of multiple rings for increased filter area while eliminating the reliability issues of separate components through unified construction
3Ease of manufacture
If multiple components are joined by welding, then assembly is achieved, but manufacturing time and cost increase
Solution Approach 1:
The filter element is manufactured as a single integrated component using additive manufacturing, combining what would otherwise require multiple welding operations. This eliminates plural manufacturing steps, reducing both time and cost while maintaining assembly capability
4Ease of manufacture
If wire mesh filters are used, then manufacturing is simplified, but filter rating degrades due to strand movement
Solution Approach 1:
The filter uses porous walls with fixed aperture sizes instead of woven strands. This porous structure prevents the strand movement and passage opening issues of wire mesh filters while maintaining manufacturing simplicity through additive manufacturing processes
Solution Approach 2:
The integrated filter element combines structural support and filtration function in a unified porous structure, eliminating the need for separate wire mesh assemblies that are prone to degradation from strand movement
5Ease of manufacture
If wire mesh filters are used, then manufacturing is easier, but pressure drop increases due to smaller surface area
Solution Approach 1:
The porous wall structure provides large surface area for filtration within a compact volume, reducing pressure drop compared to wire mesh filters. The additive manufacturing process easily creates these porous structures without compromising manufacturing ease
Solution Approach 2:
The filter utilizes three-dimensional porous structures within the disk rings, adding vertical filtration surface area beyond the traditional two-dimensional wire mesh plane. This increases effective filter area without increasing footprint, reducing pressure drop
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a reduced mass and pressure drop, enhanced filtration stability, and simplified manufacturing, while preventing wear and thermal expansion-related issues, resulting in a more efficient and durable fluidic filter for space propulsion applications.
Implementation Method 1
At least a portion of the plurality of ridges facing the second flow passages is permeable to the fluid so as to allow passage of the fluid from the second flow passages to the first flow passage
Data Source
AI summary
A fluidic filter for filtering a fluid includes a filter housing having an inlet part, an outlet part and a housing part, and a filter element having an inlet side and an outlet side. The filter element is housed inside the housing part of the filter housing and includes a first flow passage that extends along a longitudinal direction of the filter element and is connected to the outlet part, and a plurality of ridges extending along the longitudinal direction. A plurality of second flow passages respectively are formed between ridges and an inner surface of the housing part, allowing the fluid to flow from the inlet side of the filter element along the longitudinal direction. At least a portion of the plurality of ridges facing the second flow passages is permeable to the fluid so as to allow passage of the fluid from the second flow passages to the first flow passage. A tip portion of each of the plurality of ridges is joined to the inner surface of the housing part along a part of the tip portion of the respective ridge in the longitudinal direction.