Structured variable porosity mixing and/or combustion device and process

Abstract

A porous matrix structure for fluid mixing, such as for a burner. The matrix structure includes contiguous fluid flow channels extending through two or more matrix layers or sections. Each of the contiguous fluid flow channels comprises a different channel configuration in each of the two or more layers. Each of the contiguous fluid flow channels is separate from adjacent contiguous fluid flow channels to minimize cross flow. Each fluid flow channel changes in size and/or is divided into subchannels at each layer change.

What is claimed is: 
     
         1 . A matrix structure comprising contiguous fluid flow channels extending through two or more layers, wherein each of the contiguous fluid flow channels comprises a different channel configuration in each of the two or more layers. 
     
     
         2 . The matrix structure of  claim 1 , wherein each of the contiguous fluid flow channels within a layer is separate from adjacent contiguous fluid flow channels to minimize cross flow. 
     
     
         3 . The matrix structure of  claim 1 , wherein each of the contiguous fluid flow channels includes fluid flow subchannels in at least one of the two or more layers. 
     
     
         4 . The matrix structure of  claim 1 , wherein each of the contiguous fluid flow channels includes a first configuration in a first layer and a second configuration in a second layer, and the second configuration includes inner dividing walls within the contiguous fluid flow channels. 
     
     
         5 . The matrix structure of  claim 4 , wherein the first configuration comprises a single fluid flow channel, and the second configuration includes two or more fluid flow subchannels. 
     
     
         6 . The matrix structure of  claim 1 , wherein the different configuration in each of the two or more layers comprises a different size and/or different channel divisions. 
     
     
         7 . The matrix structure of  claim 1 , comprising:
 a first matrix material layer; and   a second matrix material layer adjacent the first matrix material layer, wherein each of the contiguous fluid flow channels is divided into two fluid flow subchannels within the second matrix material layer.   
     
     
         8 . The matrix structure of  claim 7 , further comprising:
 a third matrix material layer adjacent the second matrix material layer, wherein each of the contiguous fluid flow channels is divided further into a plurality of fluid flow subchannels within the third matrix material layer.   
     
     
         9 . The matrix structure of  claim 1 , further comprising an array of the contiguous fluid flow channels, wherein a first section of the array includes contiguous fluid flow channels having a first fluid flow subchannel configuration, and a second section of the array includes contiguous fluid flow channels having a second fluid flow subchannel configuration. 
     
     
         10 . A burner or mixer comprising the porous matrix structure of  claim 1 . 
     
     
         11 . A matrix structure comprising:
 a first matrix material layer;   a second matrix material layer; and   contiguous fluid flow channels extending through the first matrix material layer and the second matrix material layers, wherein the each of the contiguous fluid flow channels comprises a first channel configuration within the first matrix material layer and a second channel configuration within the second matrix material layer.   
     
     
         12 . The matrix structure of  claim 11 , wherein the second channel configuration has a reduced size and/or divided fluid flow subchannels, compared to the first channel configuration. 
     
     
         13 . The matrix structure of  claim 11 , further comprising:
 a third matrix material layer; and   each of the contiguous fluid flow channels comprises a third channel configuration within the third matrix material layer.   
     
     
         14 . The matrix structure of  claim 13 , wherein the second channel configuration has a reduced size and/or divided fluid flow subchannels, compared to the first channel configuration, and the third channel configuration has a further reduced size and/or further divided fluid flow subchannels, compared to the second channel configuration. 
     
     
         15 . The matrix structure of  claim 11 , wherein the each of the contiguous fluid flow channels is separate from adjacent contiguous fluid flow channels to minimize cross flow. 
     
     
         16 . The matrix structure of  claim 11 , wherein each of the contiguous fluid flow channels includes fluid flow subchannels within the second channel configuration. 
     
     
         17 . The matrix structure of  claim 11 , wherein the first channel configuration comprises a single flow channel, and the second channel configuration includes two or more fluid flow subchannels. 
     
     
         18 . The matrix structure of  claim 11 , wherein each of the contiguous fluid flow channels includes inner dividing walls forming the second channel configuration. 
     
     
         19 . The matrix structure of  claim 11 , further comprising
 a third matrix material layer, wherein each of the contiguous fluid flow channels comprises a third channel configuration within the third matrix material layer;   wherein the first channel configuration includes a single fluid flow channel, the second channel configurations includes two fluid flow subchannels, and the third channel configuration includes four fluid flow subchannels.   
     
     
         20 . A method of delivering a gas and/or oxidant mixture to a burner, the method comprising passing the gas and/or oxidant mixture through a matrix structure including contiguous fluid flow channels extending through first and second matrix material layers, wherein each of the contiguous fluid flow channels comprises a first channel configuration within the first matrix material layer and a second channel configuration within the second matrix material layer.