Monolithic Pump Inlet Housing With Lattice Filter for Low Pressure Drop

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Solution Overview

Problem

Pump inlet housings often require separate filters that are expensive, have long lead times, limited size and shape options, and may be large and heavy to withstand operational pressures, lacking structural support.

Innovation Solution

A monolithic additively manufactured pump inlet housing and filter are integrated using laser bed powder fusion, allowing for a lattice filter design that provides structural support and optimized flow characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate filter is used in the pump inlet housing, then filtering function is provided, but device complexity increases and assembly becomes more complex

Engineering Contradiction:

Improvefiltering functionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filter and pump inlet housing are merged into a single monolithic component manufactured via additive manufacturing. The filter media is integrated within the housing structure, eliminating separate filter assemblies and reducing overall device complexity while maintaining the filtering function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic pump inlet housing serves multiple functions simultaneously: it provides the housing structure, contains the filter media for particle removal, and maintains pressure containment. This multi-functionality eliminates the need for separate filter components and simplifies assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional filters are used, then filtering is achieved, but delivery lead times are long and cost is high

Engineering Contradiction:

Improvefiltering functionVSAvoiddelivery lead time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By combining the filter media and housing into a single monolithic component, the invention eliminates the need for separate filter procurement and assembly. The additive manufacturing process allows for direct production of the integrated component, significantly reducing delivery lead times and manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention changes the manufacturing approach from traditional separate component fabrication to monolithic additive manufacturing. This parameter change in the manufacturing process enables faster production and delivery while reducing overall system cost.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the pump inlet housing is designed to withstand operational pressures, then structural integrity is maintained, but the housing becomes large and heavy

Engineering Contradiction:

Improvestructural integrityVSAvoidhousing weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The lattice structure uses a porous or open-cell geometry that provides structural strength while minimizing material usage. The lattice configuration allows the housing to withstand operational pressures without requiring solid, heavy walls, thus reducing overall weight while maintaining structural integrity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The monolithic structure integrates the filter media with the housing in a composite configuration, where the lattice framework provides structural support and the filter media provides filtering function. This composite approach optimizes both strength and weight characteristics.

Inventive Principle:

Principle #40Composite materials

4Device complexity

If a monolithic additively manufactured design is used, then assembly complexity is reduced and design flexibility is enhanced, but manufacturing process complexity increases

Engineering Contradiction:

Improveassembly complexityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The invention replaces traditional mechanical assembly processes with additive manufacturing. The monolithic structure is created through layer-by-layer deposition or fusion processes, eliminating the need for separate component assembly operations and reducing overall manufacturing complexity despite the advanced manufacturing technology required.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 integrated design reduces assembly complexity, enables flexible design configurations, and enhances structural integrity while minimizing friction losses and pressure drops.

Implementation Method 1

the AM process includes applying laser bed powder fusion

Methodology Applied

Scientific EffectLaser bed powder fusion: Laser

Data Source

PatentEP4086464B1Monolithic additively manufactured pump inlet housing and filter

Publication Date: 2025.06.25 HAMILTON SUNDSTRAND CORP

Figure 1A
Figure 1B
Figure 2~3

AI summary

A method of manufacturing a pump inlet housing and filter for a pump assembly, wherein the pump inlet housing and filter are monolithic, the method has the steps of: defining a pump inlet housing (220) as a housing tubular shape with an inlet aperture boundary (230) at a housing top end (240), and an outlet aperture boundary (250) at a housing bottom end (260); defining a lattice filter (270) between the inlet and outlet aperture boundaries; and performing an additive manufacturing (AM) process to additively manufacture the pump inlet housing and the lattice filter such that the lattice filter is integral with the pump inlet housing.