3D Gradient porous structure for Phase Separation Utilizing Additive Manufacturing Methods

Disclosed herein are advantageous phase separator devices, and related methods of fabrication and use thereof. The present disclosure provides improved phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices. More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

FIELD OF THE DISCLOSURE

The present disclosure relates to phase separator devices for phase separation of feedstreams and systems/methods for utilizing and fabricating the phase separator devices and, more particularly, to porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow).

BACKGROUND OF THE DISCLOSURE

In general, there are numerous applications for structures and assemblies for flow control of fluids (e.g., liquids and gases).

An interest exists for improved systems and methods for phase separation of fluids.

These and other inefficiencies and opportunities for improvement are addressed and/or overcome by the systems, methods and devices of the present disclosure.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure provides advantageous phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices. More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

The present disclosure provides for a phase separator device including a porous structure that extends from a first end to a second end, the porous structure having an inner area having a first plurality of pores, an intermediate area having a second plurality of pores and a first outer area having a third plurality of pores; wherein the pores of the first plurality of pores are interconnected with the pores of the second plurality of pores, and the pores of the second plurality of pores are interconnected with the pores of the third plurality of pores; and wherein the porous structure is configured and dimensioned to separate a fluid mixture introduced to the first end of the porous structure into a first fluid phase flow and a second fluid phase flow.

The present disclosure also provides for a method for utilizing a phase separator device including providing a porous structure that extends from a first end to a second end, the porous structure having an inner area having a first plurality of pores, an intermediate area having a second plurality of pores and a first outer area having a third plurality of pores, and with the first plurality of pores interconnected with the second plurality of pores and the second plurality of pores interconnected with the third plurality of pores; and introducing a fluid mixture to the first end of the porous structure to separate the fluid mixture into a first fluid phase flow and a second fluid phase flow.

Any combination or permutation of embodiments is envisioned. Additional advantageous features, functions and applications of the disclosed systems, methods and devices of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.

DETAILED DESCRIPTION OF THE DISCLOSURE

The exemplary embodiments disclosed herein are illustrative of advantageous phase separator devices, and systems of the present disclosure and methods/techniques thereof. It should be understood, however, that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Therefore, details disclosed herein with reference to exemplary phase separator devices and associated processes/techniques of assembly and use are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the advantageous phase separator devices and/or alternative phase separator devices of the present disclosure.

The present disclosure provides advantageous phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices.

More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

Referring now to the drawings, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. Drawing figures are not necessarily to scale and in certain views, parts may have been exaggerated for purposes of clarity.

As shown inFIG. 1, there is illustrated a phase separator device10depicting an embodiment of the present disclosure.

Exemplary phase separator device10takes the form of a porous phase separator device10for thermal management or the like, although the present disclosure is not limited thereto.

Phase separator device10is configured and dimensioned to be utilized for phase separation of feedstreams11(e.g., two-phase fluid mixture feedstreams11).

More particularly and discussed further below, phase separator device10includes a porous (e.g., three-dimensional gradient porous) phase separator structure12that is configured and dimensioned to be utilized for phase separation of fluid mixtures11(e.g., to separate a two-phase fluid mixture11) to a first fluid phase flow26(e.g., to a liquid flow26) and to a second fluid phase flow28(e.g., to a gas flow28).

In general, phase separator device10includes a porous structure12that extends from a first end14to a second end16. In exemplary embodiments, the porous structure12is substantially cylindrical, although the present disclosure is not limited thereto. Rather, it is noted that porous structure12can take a variety of shapes and/or forms.

In certain embodiments, at least a portion of porous structure12is fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques. In some embodiments, the porous structure12itself can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

The porous structure12includes an inner area18having a first plurality of pores, an intermediate area20having a second plurality of pores, and a first outer area22having a third plurality of pores. In some embodiments, phase separator device10includes a second outer area24having a fourth plurality of pores.

As discussed further below, it is noted that phase separator device10can include other numbers of outer areas each having a plurality of pores (e.g., a third outer area (not shown) surrounding second outer area24, the third outer area having a fifth plurality of pores (with the pores of second outer area24interconnected with and larger than the pores of third outer area); a fourth outer area (not shown) surrounding third outer area, the fourth outer area having a sixth plurality of pores (with the pores of third outer area interconnected with and larger than the pores of fourth outer area); etc.).

The first plurality of pores of the inner area18are interconnected with the second plurality of pores of the intermediate area20, and the second plurality of pores of the intermediate area20are interconnected with the third plurality of pores of the first outer area22.

The fourth plurality of pores of the second outer area24(if present) are interconnected with the third plurality of pores of the first outer area22(and the fifth plurality of pores of the third outer area (if present) are interconnected with the fourth plurality of pores of the second outer area24).

In exemplary embodiments, the first plurality of pores of the inner area18are larger than the second plurality of pores of the intermediate area20, and the second plurality of pores of the intermediate area20are larger than the third plurality of pores of the first outer area22, and the third plurality of pores of the first outer area22are larger than the fourth plurality of pores of the second outer area24(if present). Similarly, the fourth plurality of pores of the second outer area24are larger than the pores of third outer area (if present), and the pores of the third outer area (if present) are larger than the pores of the fourth outer area (if present), etc.

In certain embodiments, the pores of the first plurality of pores of the inner area18have a mean pore size that is greater than or equal to 100 micrometers, and the pores of the fourth plurality of pores of the second outer area24have a mean pore size of at least about 0.10 micrometers, preferably a mean pore size of about 0.50 micrometers.

The first, second, third and fourth plurality of pores (and fifth plurality, etc.) can extend from the first end14of the porous structure12to the second end16, although the present disclosure is not limited thereto.

In regards to the pores of the first, second, third and fourth plurality of pores (and fifth plurality, etc.), it is noted that the pores can be classified by their size and/or shape. In regards to the pore size, the numerical value represents the mean pore size as one will recognize there will be a distribution in pore sizes for each size category. Furthermore, the pores can take the form of a variety of shapes and/or forms. For example, the pores can be nearly spherical in certain embodiments, or irregularly shaped where the average x-y-z dimensions differ (e.g., greatly differ) from each other in other embodiments. It is noted that the pores can be randomly oriented (e.g., isotropic), or intentionally oriented to provide anisotropic structures to control flow in specific directions. An example of this would be equal flow in the x and y directions and limited flow in the z direction due to the orientation of the pores.

It is noted that the porous structure12can have pore size gradients of the pores of the first, second, third and fourth plurality of pores (and fifth plurality, etc.) in all three x-y-z axes. As noted and in one embodiment, the first plurality of pores of the inner area18are larger than the second plurality of pores of the intermediate area20, and the second plurality of pores of the intermediate area20are larger than the third plurality of pores of the first outer area22, and the third plurality of pores of the first outer area22are larger than the fourth plurality of pores of the second outer area24. In other embodiments, the pore sizes of the first, second, third and fourth plurality of pores (and fifth plurality, etc.) can all increase, decrease and/or vary in size when travelling from the first end14to the second16, and/or when travelling tangentially to or away from the center of inner area18.

In some embodiments, it is noted that the pores may gradually change in size from one area18,20,22,24, etc., to another. For example, the pores in the inner area18may gradually decrease in size when interconnecting with the pores of the intermediate area20. However, in other embodiments, there may be no gradual change in size from one area18,20,22,24, etc., to another.

In exemplary embodiments, the intermediate area20surrounds the inner area18, and the first outer area22surrounds the intermediate area20. The second outer area24, if present, surrounds the first outer area22. Similarly, the third outer area, if present, surrounds the second outer area24, etc.

The inner area18, the intermediate area20, and the first and second outer area22,24(and third outer area, etc.) can extend from the first end14of the porous structure12to the second end16, although the present disclosure is not limited thereto.

As shown inFIG. 1, phase separator device10can include an inlet section13that extends from the first end14of the porous structure12, and can include an outlet section15that extends from the second end16of the porous structure12.

Exemplary inlet section13is substantially cylindrical and includes an inner inlet lumen17, and exemplary outlet section15is substantially cylindrical and includes an inner outlet lumen19.

As noted, the porous structure12of device10is configured and dimensioned to separate a feedstream11(e.g., a two-phase fluid mixture stream11) that is introduced (e.g., via inner inlet lumen17of inlet section13) to the first end14of the porous structure12into a first fluid phase flow26(e.g., a liquid flow26) and a second fluid phase flow28(e.g., gas flow28).

In exemplary embodiments, the first fluid phase flow26exits the porous structure12via the fourth plurality of pores of second outer area24. It is noted that if second outer area24is not present, then first fluid phase flow26exits the porous structure12via the third plurality of pores of first outer area22. It is also noted that if third outer area is present, then first fluid phase flow26exits the porous structure12via the pores of the third outer area, etc. Stated another way, first fluid phase flow26can exit the porous structure12via the pores of the outermost outer area of porous structure12.

Second fluid phase flow28can exit the porous structure12via inner outlet lumen19of outlet section15. In certain embodiments, first fluid phase flow26is a liquid phase flow26, and second fluid phase flow28is a gas phase flow28. In other embodiments, first fluid phase flow26is a liquid phase flow26(e.g., oil or water), and second fluid phase flow28is a liquid phase flow28(e.g., oil or water).

In some embodiments, the feedstream11includes a used refrigerant (e.g., R717 (Ammonia)).

In certain embodiments, the first fluid phase flow26exits the porous structure12via the pores of the outermost outer area of porous structure12via at least one of: (i) capillary action of all the plurality of pores of the porous structure12(e.g., capillary action of the first, second, third and fourth plurality of pores); (ii) temperature gradients associated with the porous structure12; (iii) pressure gradients associated with the porous structure12; (iv) pore size gradients of all the plurality of pores of the porous structure12(e.g., pore size gradients of the first, second, third and fourth plurality of pores); and/or (v) gravity with or without enhancement using centrifugal force (e.g., artificial gravity).

In use, exemplary device10utilizes an interconnected three-dimensional network distribution of pores (e.g., the pores of the first, second, third and fourth plurality of pores of structure12), with the pores designed to separate a two phase mixture11(e.g., a gas/liquid mixture11or a liquid/liquid mixture11) flowing into the device10into separate exit streams26,28. Exemplary exit stream28(second fluid phase flow28) can be the gas phase and the other exit stream26(first fluid phase flow26) can be the liquid phase. The liquid phase of mixture11is captured in the pores of structure12through capillary action and extracted from the device10using a combination of temperature gradients, pressure gradients, pore size gradients, and/or gravity with or without enhancement using centrifugal force (artificial gravity).

One application for device10is for thermal management where a refrigerant such as R717 (ammonia) is used to cool a laser diode for a directed energy weapon application. The refrigerant enters the laser diode block as a liquid and the heat from the device boils the coolant creating a two-phase mixture11(liquid and gas stream11). The phase separator device10then separates the liquid26from the gas28, and the liquid26can be cooled and returned to the cooling loop or storage reservoir for reuse. The gas phase28can be discarded as waste or optionally be sent to a condenser system to convert back to a liquid phase for reuse.

Other applications for device10can be separation of two or more immiscible liquids (e.g., oil and water, in the case of an environmental spill of petroleum products into oceans, lakes, ponds, rivers, etc.).

Another application for device10can be the separation of liquid/liquid mixtures11or gas/liquid mixtures11(e.g., in a manufacturing process such as production of biodiesel or glycerin).

The phase separator device10can be utilized in a continuous process such as in pipelines and/or transfer of fluids from one tank to another. Device10may also be used in a batch process where fluid11is extracted from a bio-reactor, separated (e.g., into streams26,28), and then one phase (26or28) returned back to the bio-reactor for further processing and the other (26or28) sent off as final product or for additional processing.

The gradient in pore sizes and shape and size of the device10can be nearly infinitely adjusted to tune the phase separator device10for substantially maximum efficiency (100% separation of fluids11). The device10can also be scaled for very small flow rates (e.g., micro-fluidics) to large flow rates (e.g., industrial manufacturing/cooling, etc.).

In addition, the materials of construction of device10and/or structure12can be a material that can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques, thereby allowing for compatibility to a wide variety of fluids.

Future studies include simulations and modeling (e.g., using first principal theory) to optimize the size and/or density of pores to capture fluid via capillary action and to further develop the means to extract the fluid from the pores in continuous operations.

All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt. % to 25 wt. %,” etc.). “Combinations” is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “some embodiments”, “an embodiment”, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. A “combination thereof” is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed.

Although the systems and methods of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited to such exemplary embodiments and/or implementations. Rather, the systems and methods of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and/or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, and substitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure.