A wall-type flow-around filter module, filter material and oil-gas separator

Abstract

The present invention discloses a wall-type bypass filter module, a filter material and an oil-gas separator, wherein the wall-type bypass filter module comprises at least one porous filter medium layer (101) and at least one bypass filter layer, wherein the bypass filter layer forms a flow channel for airflow to bypass, and the flow channel has an air inlet and an air outlet. The wall-type bypass filter module, the filter material and the oil-gas separator provided by the present invention can improve the filtering performance of the emission particles in the engine crankcase blowby while separating the oil mist in the engine crankcase blowby.

Description

Technical Field

[0001] The invention relates to the technical field of oil-gas separator inspection, and in particular to a wall-type flow-around filter module, a filter material and an oil-gas separator. Background Art

[0002] The main pollutants emitted by diesel engines are combustion exhaust gases directly discharged from the exhaust pipe and crankcase blowby gases. As laws and regulations on exhaust pipe emissions become increasingly stringent, technical improvements have mainly focused on controlling combustion exhaust gases directly discharged from the exhaust pipe, and have achieved remarkable results. The National VI regulations count crankcase blowby gases as part of emission pollutants, and the proportion of pollutants in crankcase blowby gases in the total pollutants of diesel engines has increased accordingly. To further reduce pollutant emissions, crankcase blowby gases must be controlled.

[0003] Crankcase blowby refers to the combustible mixture and burned gas that leak from the combustion chamber into the crankcase through the gap between the piston group and the cylinder during the compression, combustion and expansion process of the internal combustion engine when the internal combustion engine is running. Blowby gas entering the crankcase will increase the crankcase temperature and increase the evaporation of the oil in the oil pan. In addition, some parts in the crankcase are splash lubricated, and the splash lubrication process will produce oil mist, which makes the blowby gas contain not only residual fuel and exhaust gas and carbon black produced by combustion, but also a lot of oil. If the blowby gas cannot be discharged in time, the fuel vapor in the blowby gas will condense, causing the oil to deteriorate, resulting in poor lubrication, thereby causing wear of parts and increased oil consumption; if the blowby gas cannot be discharged in time, the crankcase pressure will be too high, causing the engine to leak air and oil. Therefore, the crankcase of the internal combustion engine needs a ventilation system to handle the blowby gas, separate the oil in the blowby gas, and maintain the crankcase pressure within an appropriate range.

[0004] The crankcase ventilation system is divided into a natural ventilation system and a forced ventilation system. The natural crankcase ventilation system is also called an open crankcase ventilation system. Its principle is to discharge the crankcase exhaust gas directly into the atmosphere; the forced crankcase ventilation system introduces the crankcase exhaust gas into the engine's intake pipe, and then burns it in the cylinder, which can reduce pollutant emissions and improve engine economy.

[0005] Problems with existing technologies:

[0006] (1) Figure 1As shown, if a forced ventilation system is used and it is not controlled, the oil vapor contained in the crankcase blowby gas will condense along the way and adsorb on the supercharger c, intercooler d, intake and exhaust valves and other parts of the intake system, thereby reducing their working performance and life; in addition, the main component of the engine oil is a mixture of heavy high molecular weight hydrocarbons and non-hydrocarbons, which is difficult to completely burn after being introduced into the combustion chamber, and it is easy to produce carbon smoke, forming carbon deposits in cylinder b, reducing the working performance of the engine a, while increasing the emission of harmful particulate matter, polluting the exhaust gas after-processor, and reducing its performance and service life. Therefore, the current technical challenges of the forced ventilation system are very large. For example, the patent "CN 111246924 A" discloses a separator product for a forced ventilation system. The use of this product achieves the purpose of separation performance through a filter medium. Compared with the products of the National Five Stage, this type of product has a new replaceable filter element product, and the filter element needs to be replaced regularly, which increases the maintenance cost and the procurement cost of the main engine manufacturer. The market maintenance of commercial vehicles has not yet reached the standard level of passenger vehicles, and the maintenance of new parts users is also a challenge. First, it increases the maintenance cost. Second, if the maintenance is not timely, the crankcase pressure will increase or the safety valve will open, causing pollutants to be discharged into the atmosphere.

[0007] (2) There are also two structural designs for respirators with open ventilation systems. One is a filter-type design, such as the patented product patent "CN 111246924 A" analyzed above, and its disadvantages are as above. The other structure is a filter-free design, such as the patent "CN106471227A", which mostly uses physical structures such as acceleration orifice plates, maze collisions, etc. This type of structure can achieve a certain degree of separation during work, but it is difficult to achieve a level of 6*10^11 or lower in the separation of PN, and PN specifically refers to particles larger than 23nm. This is mainly because the particle size in PN is irregular motion, the solution in the patent "CN106471227A" has a short motion path, and lacks an effective capture medium. It is impossible to meet the requirements for PN in the National VI emission regulations. Summary of the invention

[0008] Based on the above problems, the purpose of the present invention is to provide a wall-type flow-around filter module and an oil-gas separator, which can optimize and improve the separation performance of PN in automobile exhaust.

[0009] In order to overcome the deficiencies of the prior art, one of the technical solutions provided by the present invention is:

[0010] A wall-type bypass filter module comprises at least one porous filter medium layer and at least one bypass filter layer, wherein the bypass filter layer is formed with a flow channel for air flow to bypass, and the flow channel has an air inlet and an air outlet.

[0011] In some embodiments, the flow-around filter layer is arranged between two porous filter medium layers, and the flow channel is connected to the porous filter layers.

[0012] In some embodiments, the flow-around filtration layer includes two microporous channel layers, the microporous channel layers are microporous mesh structures, and the micropores of the two microporous channel layers are arranged in an interlaced manner to form the flow channel between the two microporous channel layers.

[0013] In some embodiments, the microporous channel layer and the porous filter medium layer, and two adjacent microporous channel layers are fixedly connected to each other.

[0014] In some embodiments, the micropores are one or more of square, circular, elliptical, and diamond-shaped.

[0015] In some of the embodiments, a plurality of channels arranged at intervals are formed in the flow-around filter layer, and the plurality of channels are interconnected via the porous filter medium layer to form the flow channel.

[0016] In some of the embodiments, the flow-around filter layer is made of an oleophobic material.

[0017] In some of the embodiments, the porous filter medium layer is made of an oleophilic material.

[0018] In order to overcome the deficiencies of the prior art, another technical solution provided by the present invention is:

[0019] An oil-gas separator comprises the wall-type flow-around filter module described in any one of the above.

[0020] In some embodiments, the method comprises a tank body and a central frame, wherein the central frame is installed in the tank body, and the at least one porous filter medium layer and the at least one flow-around filter layer are wound around the central frame.

[0021] In some of the embodiments, the central skeleton includes an upper end cover and a central support tube arranged on the upper end cover, the at least one layer of porous filter medium layer and the at least one layer of flow-through filter layer are wound on the central support tube and abut against the upper end cover, the upper end cover is provided with a plurality of air outlet holes, the outer periphery of the upper end cover is provided with a circle of clamps that seal with the tank body, and the upper end cover is buckled and connected to the clamps.

[0022] In some embodiments, the lower end of the central support tube abuts against the bottom of the tank body, the lower side wall of the central support tube is provided with at least one exhaust port, and the upper end of the central support tube is provided with a safety valve.

[0023] In some embodiments, the invention comprises a tank body and a filter element mounting member mounted in the tank body, wherein the at least one porous filter medium layer and the at least one flow-around filter layer are stacked and arranged in the filter element mounting member.

[0024] In some of the embodiments, the filter element mounting member includes an end cover portion and a mounting portion arranged at the lower end of the end cover portion, the side of the mounting portion has a mounting opening for the wall-type flow-through filter module to extend into, the bottom of the mounting portion is provided with an oil return port, and the end cover portion is provided with an air outlet.

[0025] In order to overcome the deficiencies of the prior art, another technical solution provided by the present invention is:

[0026] A wall-type flow-around filter material comprises a porous filter medium layer and microporous channel layers arranged on both sides of the porous filter medium layer in the thickness direction.

[0027] In some embodiments, the microporous channel layer is composited on the surface of the porous filter medium layer.

[0028] Compared with the prior art, the advantages of the present invention are:

[0029] 1. The bypass filter layer has a flow channel for airflow to bypass, which can lengthen the channel length of the gaseous fluid, increase the probability of collision between particles in the airflow and the porous filter medium, and improve the separation performance of PN. It can also provide a channel other than the porous filter medium. When the resistance of the porous filter medium increases, more airflow bypasses the bypass filter layer, so that the flow resistance of the entire filter module will not increase significantly in the initial and use states;

[0030] 2. The bypass filter layer is composed of two layers of microporous channel layers. The microporous channel layer is a microporous mesh structure with simple structure and convenient production;

[0031] 3. The bypass filter layer is made of oleophobic material, and the separated oil droplets can settle quickly, extending the service life of the filter module;

[0032] 4. When used in oil-gas separators, the porous filter medium layer and the microporous channel layer are wound on the central skeleton, which can accommodate the most filter media in the smallest space;

[0033] 5. A safety valve is installed in the central support tube of the central skeleton. The structure is compact and the internal space of the central support tube is utilized. When the internal pressure of the oil-gas separator is too high, the airflow can enter the central support tube through the lower end of the central support tube to lift the safety valve, so that the airflow can be discharged through the upper end of the central support tube. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0035] Figure 1 It is a structural schematic diagram of a forced ventilation system in the prior art;

[0036] Figure 2 This is a schematic structural diagram of a wall-type flow-around filtration module embodiment 1 of the present invention;

[0037] Figure 3 This is a schematic diagram of the structure of a microporous channel layer in an embodiment of the present invention;

[0038] Figure 4 This is a schematic diagram of the structure of another microporous channel layer in an embodiment of the present invention;

[0039] Figure 5 This is a schematic structural diagram of a wall-type flow-around filtration module embodiment 2 of the present invention;

[0040] Figure 6 This is a structural schematic diagram of an oil-gas separator embodiment 1 of the present invention;

[0041] Figure 7 A top view of the central skeleton in Example 1 of the present invention;

[0042] Figure 8 This is a structural schematic diagram of an oil-gas separator embodiment 2 of the present invention (without the tank body);

[0043] Fig. 9 for Figure 8 A top view of

[0044] Fig.10 It is a schematic structural diagram of a wall-type flow-around filter material of the present invention;

[0045] in:

[0046] a. Generator; b. Cylinder; c. Supercharger; d. Intercooler;

[0047] 100, wall-type flow-around filter module; 101, porous filter medium layer; 102, microporous channel layer; 103, oil-resistant and temperature-resistant material; 103a, channel; 200, airflow;

[0048] 1. Tank body; 1-1. Exhaust pipe;

[0049] 2. Central skeleton; 2-1. Upper end cover; 2-1a. Air outlet; 2-2. Central support tube; 2-2a. Exhaust port; 2-2b. Boss;

[0050] 3. Safety valve; 3-1. Valve cover; 3-2. Support foot; 3-2a. Clamp foot;

[0051] 4. Clamp;

[0052] 5. Sealing ring;

[0053] 6. Filter element mounting part; 6-1. End cover; 6-1a. Gas outlet; 6-2. Mounting part; 6-2a. Oil return port. DETAILED DESCRIPTION

[0054] The above scheme is further described below in conjunction with specific examples. It should be understood that these examples are used to illustrate the present invention and are not limited to the scope of the present invention. The implementation conditions adopted in the examples can be further adjusted according to the conditions of the specific manufacturer, and the unspecified implementation conditions are usually the conditions in conventional experiments.

[0055] See also Figure 2 , a structural schematic diagram of embodiment 1 of a wall-type bypass filter module 100 is provided, which includes at least one porous filter medium layer 101 and at least one bypass filter layer, the bypass filter layer forms a flow channel for the air flow 200 to bypass, and the flow channel has an air inlet and an air outlet, so that the mixed gas can bypass in the bypass filter layer.

[0056] In this example, the wall-type bypass filter module 100 includes three porous filter medium layers 101 and two bypass filter layers. The bypass filter layer is arranged between the two porous filter medium layers 101. The flow channel is connected to the porous filter medium layer 101. The airflow 200 entering the flow channel can collide with the porous filter medium layer 101, which can increase the collision probability of the airflow 200 and the porous filter medium layer 101 and improve the PN separation performance. It should be understood that during implementation, the number of porous filter medium layers 101 and bypass filter layers can be set as needed, and the present invention does not limit it. Preferably, the bypass filter layer is arranged between the two porous filter medium layers 101.

[0057] In order to facilitate the production and processing of the bypass filter layer, in this example, the bypass filter layer includes two layers of microporous channel layers 102, and the microporous channel layer 102 is a microporous mesh structure. The micropores of the two layers of microporous channel layers 102 are arranged in an interlaced manner to form the above-mentioned flow channel between the two layers of microporous channel layers 102. The micropores can be square (such as Figure 3 As shown), round, oval (as shown Figure 4), or one or more of the rhombus shapes. Preferably, the bypass filter layer is made of an oleophobic material, at least containing a fluorine-containing compound, or made of a fluorine-containing compound. Thus, the separated oil droplets can settle quickly to separate from the filter module, which can extend the service life of the filter module. The porous filter medium layer 101 is made of an oleophilic material, at least containing glass fiber, or made of glass fiber.

[0058] In order to ensure the integrity of the filtration module and eliminate the large gap caused by the misalignment of the microporous channel layer 102, which affects the separation performance, the microporous channel layer 102 and the porous filter medium layer 101, as well as the two adjacent microporous channel layers 102 are fixedly connected to each other. For example, a bonding process can be used to bond and fix the microporous channel layer 102 and the porous filter medium layer 101, as well as the two adjacent microporous channel layers 102 to each other.

[0059] In other embodiments, the flow channel may be a continuous S-shaped or Z-shaped structure, see Figure 5 As shown, the flow-around filter layer is arranged between two porous filter medium layers 101. The flow-around filter layer is made of oil-resistant and heat-resistant material 103, for example, glass fiber material. A plurality of channels 103a arranged at intervals can be formed in the oil-resistant and heat-resistant material 103. The plurality of channels 103a are interconnected via the porous filter medium layer 101 to form a continuous Z-shaped flow channel.

[0060] See also Figure 6-7 The above-mentioned wall-type flow-around module is applied to an oil-gas separator, which includes a tank body 1 and a central frame 2. The central frame 2 is installed in the tank body 1, and the above-mentioned wall-type flow-around filter module 100 is wound on the central frame 2.

[0061] Specifically, the central skeleton 2 includes an upper end cover 2-1 and a central support tube 2-2 arranged on the upper end cover 2-1. The wall-type flow-through filter module 100 is wound on the central support tube 2-2 and abuts against the upper end cover 2-1. A plurality of air outlet holes 2-1a are provided on the upper end cover 2-1. In this embodiment, an axial air intake method is adopted, and the mixed gas is axially introduced into the lower end of the wall-type flow-through module 100. The filtered gas enters the air outlet pipe 1-1 at the upper end of the tank body 1 through the air outlet holes 2-1a on the upper end cover 2-1 and is discharged.

[0062] In order to facilitate the installation of the central skeleton 2, a circle of clamps 4 that are sealed with the tank body 1 is provided on the outer periphery of the upper end cover 2-1. For example, a sealing ring 5 is provided between the clamp 4 and the upper end of the tank body 1. The upper end cover 2-1 is connected to the clamp 4 by snapping. The snap connection is a prior art and will not be described in detail in the present invention. A gap is provided between the clamp 4 and the outer wall of the wall-type flow-through module 100 to facilitate the injection of glue to connect the wall-type flow-through module 100 with the clamp 4 to achieve a good seal.

[0063] In order to improve the compactness of the oil-gas separator, the lower end of the central support tube 2-2 is abutted against the bottom of the tank body 1, and at least one exhaust port 2-2a is provided on the lower side wall of the central support tube 2-2. At the same time, a safety valve 3 is provided at the upper end of the central support tube 2-2. When the internal pressure of the oil-gas separator is too high, the mixed gas enters the central support tube 2-2 through the exhaust port 2-2a and lifts the safety valve 3 before entering the outlet pipe 1-1 for discharge.

[0064] Among them, the safety valve 3 includes a valve cover 3-1 and a plurality of support feet 3-2 arranged at intervals along the circumferential direction at the lower end of the valve cover 3-1. The valve cover 3-1 covers the pipe opening at the upper end of the central support tube 2-2, and a circle of bosses 2-2b are provided on the inner wall of the pipe opening. At the same time, a clamping foot 3-2a matching the boss 2-2b is provided at the lower end of the support foot 3-2. When the air pressure in the oil-gas separator is too high, the mixed gas enters the central support tube 2-2 through the exhaust port 2-2a to lift the safety valve 3, and the clamping foot 3-2a abuts against the boss 2-2b to avoid separation of the safety valve 3 from the central support tube 2-2, and the mixed gas is discharged through the gap between two adjacent support feet 3-2. When the air pressure in the oil-gas separator returns to normal, the safety valve 3 falls and resets.

[0065] See also Figure 8-9 , is another embodiment of the oil-gas separator, comprising a tank body 1 and a filter element mounting member 6 installed in the tank body 1, at least one porous filter medium layer 101 and at least one bypass filter layer are stacked and arranged in the filter element mounting member 6.

[0066] Specifically, the filter element mounting member 6 includes an end cover portion 6-1 and a mounting portion 6-2 arranged at the lower end of the end cover portion 6-1. The side wall of the mounting portion 6-2 has a mounting opening for the wall-type flow-around module 100 to extend into. An oil return port 6-2a is provided at the bottom of the mounting portion 6-2, and a gas outlet 6-1a is provided at the end cover portion 6-1. In this example, a side air intake method is adopted, and the mixed gas enters through the side wall of the mounting portion 6-2. The separated oil mist particles drip to the bottom of the mounting portion 6-2 and are discharged through the oil return port 6-2a, and the filtered gas is discharged through the gas outlet 6-1a.

[0067] See also Fig.10 The present invention also provides a wall-type flow-around filter material, comprising a porous filter medium layer 101, and microporous channel layers 102 arranged on both sides of the porous filter medium layer 101 in the thickness direction, wherein the microporous channel layers 102 are microporous mesh structures. Preferably, the microporous channel layers 102 are compounded on the surface of the porous filter medium layer 101. The wall-type flow-around filter material is wound or stacked in sequence, while ensuring that the micropores of two adjacent microporous channel layers 102 are staggered, so as to obtain the above-mentioned wall-type flow-around filter module 100, which is convenient for production.

[0068] The above examples are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A wall-type flow-around filter module, characterized in that: It comprises a porous filter medium layer (101) and at least one bypass filter layer, wherein the bypass filter layer forms a flow channel for airflow to bypass, and the flow channel has an air inlet and an air outlet; The bypass filter layer is arranged between two porous filter medium layers (101), and the flow channel is connected to the porous filter medium layers (101); The bypass filtration layer comprises two microporous channel layers (102), the microporous channel layers (102) being a microporous mesh structure, the micropores of the two microporous channel layers (102) being arranged in an interlaced manner to form the flow channel between the two microporous channel layers (102); The microporous channel layer (102) and the porous filter medium layer (101), and two adjacent microporous channel layers (102) are fixedly connected to each other; The bypass filter layer is made of an oleophobic material, and the porous filter medium layer (101) is made of an oleophilic material.

2. The wall-type flow-around filter module according to claim 1, characterized in that: The micropores are in one or more of square, circular, elliptical and diamond shapes.

3. An oil-gas separator, characterized in that: It comprises the wall-type flow-around filtration module as described in claim 1 or 2.

4. The oil-gas separator according to claim 3, characterized in that: It comprises a tank body (1) and a central frame (2), wherein the central frame (2) is installed in the tank body (1), and the porous filter medium layer (101) and at least one layer of flow-through filter layer are wound around the central frame (2) in a circumferential direction.

5. The oil-gas separator according to claim 4, characterized in that: The central skeleton (2) comprises an upper end cover (2-1) and a central support tube (2-2) arranged on the upper end cover (2-1); the porous filter medium layer (101) and at least one layer of bypass filter layer are wound on the central support tube (2-2) and abut against the upper end cover (2-1); a plurality of air outlet holes (2-1a) are provided on the upper end cover (2-1); a circle of clamps (4) that are sealed with the tank body (1) are provided on the outer periphery of the upper end cover (2-1); and the upper end cover (2-1) is snap-connected to the clamps (4).

6. The oil-gas separator according to claim 5, characterized in that: The lower end of the central support tube (2-2) abuts against the bottom of the tank body (1), the lower side wall of the central support tube (2-2) is provided with at least one exhaust port (2-2a), and the upper end of the central support tube (2-2) is provided with a safety valve (3).

7. The oil-gas separator according to claim 3, characterized in that: It comprises a tank body and a filter element mounting member (6) mounted in the tank body (1); the porous filter medium layer (101) and at least one flow-around filter layer are stacked and arranged in the filter element mounting member (6).

8. The oil-gas separator according to claim 7, characterized in that: The filter element mounting member (6) comprises an end cover portion (6-1) and a mounting portion (6-2) arranged at the lower end of the end cover portion (6-1); a side portion of the mounting portion (6-2) has a mounting opening for the wall-type bypass filter module to extend into; an oil return port (6-2a) is provided at the bottom of the mounting portion (6-2); and the end cover portion (6-1) is provided with a gas outlet (6-1a).

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