Residential hydromagnetic, sediment and air separation equipment with maintenance indicator

Abstract

A separation device features a coalescing medium and a magnetic separation insert. The coalescing media includes a vertically assembled perforated sheet having a surface with an opening. These sheets form a coalescence medium interior space in the separation chamber and are configured and shaped to slow down the hydraulic fluid and enable coalescence of entrained gases, ferromagnetic or ferritic particles, and other solids and exit from the hydraulic fluid via coalescence caused by the hydraulic fluid contacting and flowing through the coalescence medium. A magnetic separation insert is coupled to the bottom portion of the separation apparatus and disposed in the coalescence media interior space and has a non-magnetic sleeve surrounding a removable magnet insert that generates a magnetic field to attract and collect ferromagnetic or ferritic particles on the non-magnetic sleeve, these particles coalesce and exit from the hydraulic fluid and can be removed from the interior of the non-magnetic sleeve to release ferromagnetic or ferritic particles attracted and collected on the non-magnetic sleeve, so that the released ferromagnetic or ferritic particles fall to the bottom portion of the separation chamber.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of provisional patent application serial number 63 / 357,776 filed on July 1, 2022, which is hereby incorporated by reference in its entirety. Background Art 1. Technical Field

[0003] The present invention relates to a sediment and air separation plant; and more particularly to a residential sediment and air separation plant.

[0004] 2. Brief Description of Related Art Small coalescing removal separators are devices commonly installed on residential hydronic HVAC systems to remove entrained gases (such as air) and solid particles (such as dirt and iron oxide) from the fluid flowing through the system. Gases trapped in hydronic systems cause potentially harmful corrosion. Solid particulate matter collects in sediments that can foul moving parts in pumps or valves, damage sensors in the system, and clog heat exchangers and boilers, reducing system efficiency. Magnetic or ferrimagnetic particles can become trapped in pumps with electronically commutated motors where the presence of magnets will collect these particles, which foul moving parts, reduce pump efficiency, and can damage the pump.

[0005] Residential coalescing removal separators work by passing HVAC system fluid through a coalescing media into a chamber and back into the system. The action of passing the fluid through the coalescing media enables entrained gases and particles to be removed from the system. The coalescing media disrupts the fluid flow and slows the fluid velocity, which allows gas bubbles to come out of solution and float to the top of the main separator chamber through their natural buoyancy to be discharged from the system. Likewise, the reduction in fluid velocity allows solids in the fluid that are heavier than the system fluid to come out of solution and fall to the bottom of the chamber to be removed later by a blowdown action. The blowdown action involves opening a valve or drain at the bottom of the removal separator chamber to the atmosphere, thereby using the difference between atmospheric pressure and the system pressure inside the chamber to squeeze out the solid contaminants that were displaced from the solution as it passed through the coalescing media. The coalescing media also provides a surface for dissolved gases and solids to collect or coalesce around. As more dissolved gases or solids pass through the coalescing media, the molecules will continue to coalesce until they have enough buoyancy to float to the top or are heavy enough to fall to the bottom.

[0006] The separator may require a magnetic separation option to effectively remove sediments containing primarily black iron oxide (also known as magnetite) or other ferromagnetic particles suspended in the water.

[0007] Disadvantages of the above known devices

[0008] There are many issues with current residential hydro separators. The coalescing media found in current residential separators can significantly increase the pressure drop across the unit, which can negatively impact overall system efficiency. Another issue is that, due to their design, current residential separators may not be effective in removing gases or solids. Current residential hydro separators with magnetic separation options face their own unique set of challenges. Most magnetic separation products do not do an effective enough job of removing magnetite or other ferromagnetic particles from hydronic system fluids. Residential separators with magnetic separation options do not provide any visual indicators to the homeowner or regular maintenance personnel to know when the system needs to be serviced to remove any sediment or magnetite that has collected in the separator. Summary of the invention

[0009] The invention described herein is a residential hydrodynamic separator that improves the pressure drop characteristics across the separator while improving the ability of the device to more effectively remove gases and solids (including ferromagnetic particles) from system fluids.

[0010] This separator utilizes a coalescing media comprised of vertically assembled stainless steel perforated sheets arranged so that they fill a majority of the volume of the separator chamber. The sheets are assembled to one another to form a rhombus shape. Alternatively, the media may be assembled from perforated corrugated stainless steel sheets where the crowns of the corrugations may be joined together to form the rhombus shape described previously. The coalescing media may also be assembled from a single sheet where the ends are joined to form a rhombus shape. The stainless steel perforated and / or corrugated sheets have an open area of ​​58% or greater which helps to improve the pressure drop characteristics. The rhombus shaped open area facilitates the insertion of a magnetic insert within the well assembly which will be used to capture magnetite or other ferromagnetic particles entrained in the system fluid that may pass through the separator.

[0011] Fluid flows into the separator through the inlet nozzle, into the separator chamber and through the coalescing sheet media, coming into contact with the perforated stainless steel face to slow the fluid velocity, allowing entrained gas and solids to come out of solution and rise or fall respectively based on their buoyancy. The perforations in the coalescing sheet media provide multiple surfaces for dissolved gas and solids to coalesce around.

[0012] The vertical diamond shape of the coalescing sheet media serves two purposes. First, the angled edges direct the fluid through the coalescing sheet media where maximum surface area contact can occur. Likewise, when the fluid has fully passed through the coalescing sheet media, the reverse angled edges direct the fluid to the outlet or discharge nozzle to exit the separator and allow the pressure drop to recover. These movements help reduce the overall pressure drop of the coalescing separator compared to other different designs.

[0013] Second, the vertical alignment of the coalescing sheet media is rigid and resists the compressive forces to which the coalescing sheet media will be subjected during its useful life. It also resists any rotation.

[0014] The corrugated coalescing separator media is retained within the separator chamber by the chamber head at the top of the chamber and a support flange at the bottom. This provides enough open area to allow gas bubbles to rise to the top of the separator and solids to fall to the bottom while also providing ample space in the center for a magnetic separation insert.

[0015] The magnetic separation insert is composed of a non-magnetic sleeve, preferably stainless steel, which surrounds the alternating stack of magnets and carbon steel spacers. The magnets are arranged with the same magnetic poles facing each other. This has the effect of increasing the magnetic field size generated by the magnets, and the effect of increasing the magnetic flux or magnetic field number generated by the magnet arrangement. When the system fluid passes through the separation chamber, the entrained ferromagnetic particles (such as magnetite) are attracted by the magnetic field generated by the magnet in the insert and collected there. Similarly, any other ferrite solid (such as iron oxide or pure iron or steel particles) coming out of the solution via agglomeration will be attracted by the magnetic field generated by the insert. The ferromagnetic and ferrite particles collected on the magnetic separation insert further increase the magnetic field size involved and improve the collection capacity. The stack of magnets and spacers can be removed from the inside of the magnetic separation insert, which will allow the ferromagnetic particles attached to the insert and attached to each other to fall to the bottom of the residential separator. Opening the drain valve at the bottom of the separator for discharge will allow the system fluid to flush out these particles, as well as any other sediment or debris collected inside the separator chamber.

[0016] A visual indicator notifying the system operator that maintenance is required is accomplished via a sensor located outside the separator chamber. The sensor detects an increase in magnetic flux or field activity, which increases as more ferromagnetic particles collect on the magnetic insert sleeve. The sensor, whether a Hall Effect sensor, reed switch, or other type of flux sensing, detects the magnitude of the magnetic field increasing as the number of ferromagnetic and ferrite particles collect on the magnetic separator insert. When the sensor detects the expected magnetic field or flux threshold, a light on the separator will illuminate, begin to flash, or change color, indicating that maintenance is required on the separator or system. After the magnet is removed and the system is drained or flushed, the subsequent decrease in the magnetic field will cause the light to turn off. DETAILED DESCRIPTION

[0017] According to some embodiments, the present invention may take the form of a separation apparatus having a tank wall, a top, and a bottom portion that combine to form a separation chamber for processing a hydraulic fluid, and having a coalescing media and a magnetic separation insert.

[0018] The coalescing media comprises a vertically assembled perforated sheet having a surface with a plurality of openings. The vertically assembled perforated sheets are configured to form a coalescing media interior space in a separation chamber, and the vertically assembled perforated sheets are further configured and shaped to slow down a hydraulic fluid and enable entrained gas, ferromagnetic or ferrite particles and other solids to coalesce and emerge from the hydraulic fluid via a coalescing action caused by the hydraulic fluid contacting and flowing through the coalescing media.

[0019] The magnetic separation insert is coupled to the bottom portion of the separation device and is arranged in the coalescing medium internal space, and the magnetic separation insert has a non-magnetic sleeve surrounding the removable magnetic insert. The removable magnetic insert is configured to generate a magnetic field to attract and collect ferromagnetic or ferrite particles that are coalesced on the non-magnetic sleeve and come out of the hydraulic fluid, and the removable magnetic insert is also configured to be removed from the inside of the non-magnetic sleeve to release the ferromagnetic or ferrite particles attracted and collected on the non-magnetic sleeve, so that the released ferromagnetic or ferrite particles can fall to the bottom portion of the separation chamber.

[0020] The separation device may also include one or more of the following features:

[0021] The separation device may include a bottom coupling member configured on a bottom portion of the separation device; and the non-magnetic sleeve may include a sleeve coupling member configured to be removably coupled to the bottom coupling member for coupling the magnetic separation insert to the bottom portion of the separation device.

[0022] The non-magnetic sleeve may include a non-magnetic surface configured to collect ferromagnetic or ferrite particles that are attracted to the removable magnet insert by the magnetic field.

[0023] The removable magnet insert may include a handle having an insert coupling member; and the sleeve coupling member may be configured to receive the insert coupling member and couple the removable magnet insert to the non-magnetic sleeve when the removable magnet insert is inserted into the non-magnetic sleeve.

[0024] The removable magnet insert may include a rod connected to the handle; and an alternating stack of magnets and spacers configured to be slid onto the rod and retained by a bolt fastened to the end of the rod.

[0025] Alternating stacks of magnets may include opposing poles arranged such that like poles face each other and are separated by spacers.

[0026] The non-magnetic insert may be made of stainless steel; or the spacer may be made of carbon steel; or the non-magnetic insert may be made of stainless steel and the spacer may be made of carbon steel.

[0027] The vertically assembled perforated sheets may be made of stainless steel.

[0028] The vertically assembled perforated sheets can have vertical diamonds with angled edges configured to direct hydraulic fluid through the coalescing media and into the interior space of the coalescing media, and the vertical diamonds have reverse angled edges configured to direct hydraulic fluid from the interior space of the coalescing media to an outlet or discharge nozzle, exiting the separation chamber and allowing pressure drop recovery.

[0029] The vertically assembled perforated sheet may be configured as a corrugated sheet having peaks, crowns, and surfaces between the peaks and crowns.

[0030] The vertically assembled perforated sheets may be formed and assembled from a single sheet having two ends joined to form a diamond shape, or from a plurality of sheets having corresponding ends joined to form a diamond shape.

[0031] The coalescing media interior space may be 58% or more of the volume of the separator chamber as open space in order to improve the pressure drop characteristics of the separation device.

[0032] The separation device may include a maintenance indicator configured to respond to the magnetic flux generated by the magnetic separation insert and provide maintenance indicator signaling containing information about required maintenance on the separation device, including where the maintenance indicator signaling includes audio signaling and / or visual signaling.

[0033] The maintenance indicator may be configured to respond to the reduced magnetic flux as the released ferromagnetic or ferrite particles are removed from the bottom portion of the separation chamber and provide corresponding maintenance indicator signaling including information that no maintenance is required.

[0034] The maintenance indicator may include a circuit having a magnetic sensor configured to respond to magnetic flux.

[0035] The magnetic sensor may include a reed switch or a Hall Effect sensor.

[0036] The circuit may include a light configured to provide visual maintenance indicator signaling, including the light turning on / off, flashing, or changing color.

[0037] The magnetic sensor may be configured to respond to a magnetic flux exceeding a desired magnetic flux threshold.

[0038] The desired magnetic threshold may depend on and be based on the amount of ferromagnetic or ferrite particles attracted and collected onto the non-magnetic sleeve.

[0039] The separation device may include a well assembly at a bottom portion of the separation chamber, the well assembly being configured to collect the released ferromagnetic or ferrite particles.

[0040] The separation apparatus may include a chamber head at a top portion and a support flange at a bottom portion, the chamber head and the support flange being configured to retain the coalescing medium in the separation chamber.

[0041] The separation apparatus may include, or take the form of, a residential hydro-magnetic, sediment, and air separation apparatus comprising a separator tank having a separator input or inlet nozzle configured to receive a hydraulic fluid, the separator tank having a tank wall configured to form a volume / chamber within the separation chamber to process the hydraulic fluid, and the separator tank having a separator output or discharge nozzle configured to provide a treated hydraulic fluid having at least some of the entrained gas, ferromagnetic or ferritic particles, and other solids removed.

[0042] The separation apparatus may include a drain valve configured at a bottom portion of the separation chamber to open and discharge the released ferromagnetic or ferrite particles collected in the well assembly.

[0043] The separation apparatus may include a vent configured at a top portion of the separation chamber to vent entrained gas from the hydraulic fluid.

[0044] The plurality of openings formed in the surface of the vertically assembled perforated sheets also agglomerates gas and other solids in the hydraulic fluid. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The drawings, which are not necessarily drawn to scale, include the following:

[0046] Figure 1 is a side cross-sectional view of a residential hydro-magnetic, sediment, and air separation apparatus having a coalescing media with a removable magnet insert disposed therein according to some embodiments of the present invention.

[0047] Figure 2 is an illustration showing a top-down cross-sectional view of a residential hydromagnetic, sediment and air separation apparatus having coalescing media disposed therein with Figure 1 A consistent removable magnet insert is shown, and the sensor with an indicator light is also shown.

[0048] Figure 3 is a perspective view of the diamond-shaped aggregate medium that forms part of the residence, Figure 1 A top cross-sectional view of a hydraulic air and sediment separation apparatus is shown.

[0049] Figure 4 According to some embodiments of the present invention Figure 1 Illustration of a typical magnet and spacer arrangement for a removable magnet insert is shown.

[0050] Figure 5 According to some embodiments of the present invention Figure 1 A cross-sectional view of the removable magnet insert is shown.

[0051] 6 is a diagram of a circuit having a reed switch based visual maintenance indicator according to some embodiments of the present invention.

[0052] 7 is a diagram of a circuit having a Hall effect based visual maintenance indicator according to some embodiments of the present invention.

[0053] Figure 8 is a diagram showing some embodiments according to the present invention Figure 2 Illustration of a top-down cross-sectional view of a residential hydromagnetic, sediment and air separation plant shown, and also showing the magnetic field and captured magnetic particles.

[0054] Fig.9A is a side view of an individual corrugation forming part of the coalescing media shown herein.

[0055] Fig. 9B yes Fig.9A A top-down view of an individual corrugation is shown.

[0056] For consistency, similar parts or components in the figures are labeled with similar reference numbers and labels. Every lead and associated reference label for each component is not included in every figure of the drawings to reduce clutter throughout the drawings. DETAILED DESCRIPTION

[0057] According to some embodiments, and with Figures 1 to 5 and Figure 8 , Fig.9A and Fig. 9B Consistent with the illustrated embodiment, the present invention may take the form of a separation apparatus generally indicated at 10 having a tank wall 12, a top portion 14, and a bottom portion 16 which combine to form a separation chamber 18 ( Figure 2 ), and is characterized in that the coalescing medium 20 ( Figure 3 and FIG. 9A to FIG. 9B ) and magnetic separation insert 30 ( Figure 5 ). For example, the hydraulic fluid F may comprise water entrained with gas and particulate matter (eg, comprising ferromagnetic or ferritic particles FP, such as magnetite or iron oxide).

[0058] The coalescing medium 20 comprises vertically assembled perforated sheets 22, the surface 22a of the perforated sheets 22 having a plurality of openings 22b, such as Figure 3 , Fig.9A and Fig. 9BThe vertically assembled perforated sheets 22 are configured to form a coalescing medium internal space 22c ( Figure 2 and Figure 3 ), and is also configured and shaped to slow down the hydraulic fluid F and enable entrained gas, ferromagnetic or ferrite particles FP and other solids to coalesce and emerge from the hydraulic fluid F via a coalescing action, which is caused by the hydraulic fluid F contacting and flowing through the coalescing medium 20, for example, including the contact surface 22a and flowing through the opening 22b.

[0059] The magnetic separation insert 30 is coupled to the bottom portion 14 of the separation device 10 and is disposed in the coalescing medium interior space 22c and has a non-magnetic sleeve 32 surrounding a removable magnet insert 34, such as Figure 1 The removable magnetic insert 34 is configured to generate a magnetic field MF to attract and collect ferromagnetic or ferrite particles FP on the non-magnetic sleeve 32, which agglomerate and emerge from the hydraulic fluid F, for example Figure 8 The removable magnetic insert 34 is also configured to be removed from the interior of the non-magnetic sleeve 32 to release the ferromagnetic or ferrite particles FP attracted and collected on the non-magnetic sleeve 32, so that the released ferromagnetic or ferrite particles FP can fall into the bottom portion 16 of the separation chamber 12, for example, into the well assembly W described below.

[0060] Magnetic separation insert

[0061] and Figure 1 , Figure 4 and Figure 5As shown, the separation device 10 may include a bottom coupling member 14a configured on the bottom portion 16 of the separation device 10; and the non-magnetic sleeve 32 may include a sleeve coupling member 32a, the sleeve coupling member 32a configured to be coupled to the bottom coupling member 14a for coupling the magnetic separation insert 30 to the bottom portion 16 of the separation device 10, including the case where an O-ring or sealing gasket 32b is disposed between the coupling members 14a, 32a. By further example, and consistent with what is set forth herein, embodiments are contemplated, and the scope of the present invention is intended to include, for example, implementations in which the non-magnetic sleeve 32 of the magnetic separation insert 30 is coupled to the bottom portion 16 of the separation device 10 via welding; or in which the non-magnetic sleeve 32 of the magnetic separation insert 30 is formed and coupled together with the bottom portion 16 of the separation device 10 as an integral unit, or in which the sleeve coupling member 32a is removably coupled to the bottom coupling member 14a via a friction fit for coupling the magnetic separation insert 30 to the bottom portion 16 of the separation device 10. In either case, the removable magnetic insert 34 can be configured to be removed from the interior of the non-magnetic sleeve 32 to release the ferromagnetic or ferrite particles FP that are attracted and collected on the non-magnetic sleeve 32, so that the released ferromagnetic or ferrite particles FP can fall into the bottom portion 16 of the separation chamber 12, for example, into the well assembly W, as described below.

[0062] The non-magnetic sleeve 32 may include a non-magnetic surface 32 c configured to collect ferromagnetic or ferrite particles FP attracted to the removable magnet insert 34 by the magnetic field MF.

[0063] and Figure 5 As shown, the removable magnet insert 34 may include a handle portion 34a having an insert coupling member 34b; and the sleeve coupling member 32a may be configured to receive the insert coupling member 34b and couple the removable magnet insert 34 to the non-magnetic sleeve 32 when the removable magnet insert 34 is inserted into the non-magnetic sleeve 32, including the case where an O-ring or seal is arranged between the coupling members 32a, 34b. For example, and consistent with what is described herein, embodiments are contemplated, and the scope of the present invention is intended to include, for example, implementations in which the sleeve coupling member 32a may be configured to receive the insert coupling member 34b via a friction fit so as to couple the removable magnet insert 34 to the non-magnetic sleeve 32, as well as implementations by using other removable coupling techniques now known or developed in the future for removably coupling the sleeve coupling member 32a and the insert coupling member 34a together.

[0064] The removable magnet insert 34 may include a rod 34c connected to a handle 34a; and an alternating stack of magnets M and spacers S configured to slide onto the rod 34c and be retained by a bolt 34d secured to the end of the rod 34c.

[0065] The alternating stacks of magnets M may include opposing poles N, S arranged so that like poles (N, N; S, S) face each other and are separated by corresponding spacers S, e.g. Figure 1 and Figures 4 to 5 The same as shown.

[0066] The non-magnetic insert 32 may be made of stainless steel; and the spacer S may be made of carbon steel.

[0067] Vertically assembled perforated sheets

[0068] The vertically assembled perforated sheet 22 ( Figure 3 and Fig.9A , Fig. 9B ) can be made of stainless steel.

[0069] The vertically assembled perforated sheet 22 may have a vertical rhombus shape with angled edges, such as E1 ( Figure 2 ), the angled edge is configured to guide the hydraulic fluid F from the inlet I through the coalescing medium 20 and into the coalescing medium interior space 22c; and having a reverse angled edge, such as E2 ( Figure 2 ), the reverse angled edges are configured to direct the hydraulic fluid F from the coalescing medium interior space 22c through the outlet O or discharge nozzle, out of the separation chamber 10 and allow the pressure drop to recover, e.g. Figure 2 As shown. Figure 1 In the embodiment, the inlet I and the outlet O are maintained by the connector end connection.

[0070] The vertically assembled perforated sheets 22 may be configured as corrugated sheets ( Fig.9A , Fig. 9B ), which has a peak 22d, a crown 22e and a surface 22f in between.

[0071] The vertically assembled perforated sheet 22 may be formed and assembled from a single sheet with both ends joined to form a diamond shape, for example, Figure 3 or formed and assembled from a plurality of sheets having corresponding ends which are joined to form a rhombus, e.g. Fig.9A , Fig. 9B The same as shown.

[0072] The coalescing medium inner space 22 c may be formed as an open space, for example, whose volume is 58% or more of the volume of the separation chamber 18 , in order to improve the pressure drop characteristics of the separation device 10 .

[0073] Maintenance indicator

[0074] and Figure 2 6-7 , the separation device 10 may include a maintenance indicator S configured on the exterior of the separation device 10 to respond to the magnetic flux generated by the magnetic separation insert 30 and provide maintenance indicator signaling including information regarding required maintenance on the separation device 10, including instances where the maintenance indicator signaling includes audio signaling and / or visual signaling.

[0075] The maintenance indicator S can be configured to respond to the reduced magnetic flux when the released ferromagnetic or ferrite particles are removed from the bottom portion 16 of the separation chamber 18, as described below, and provide corresponding maintenance indicator signaling containing information that no maintenance is required, such as by changing color, turning off, stopping a beep, etc.

[0076] The maintenance indicator S may include a circuit as shown in FIGS. 6-7 having a magnetic sensor configured to respond to magnetic flux. The magnetic sensor may include a reed switch (FIG. 6) or a Hall effect sensor (FIG. 7). By way of example, the circuit in FIG. 6 includes a reed switch, a resistor, an LED, and a power supply arranged in series. By way of further example, the circuit in FIG. 7 includes a Hall effect sensor and a power supply arranged in parallel with the resistor and LED combination.

[0077] Each circuit may include a light (eg, an LED) configured to provide visual maintenance indicator signaling, including instances of the light or LED turning on / off, flashing, or changing color.

[0078] The magnetic sensor may be configured to respond to a magnetic flux exceeding a desired magnetic flux threshold. The desired magnetic threshold may depend on and be based on the amount of ferromagnetic or ferrite particles attracted and collected onto the non-magnetic sleeve.

[0079] Other features of separation equipment

[0080] The separation apparatus 10 may include a well assembly W at a bottom portion 16 of the separation chamber 10, the well assembly W being configured and shaped to collect the released ferromagnetic or ferrite particles.

[0081] The separation apparatus may include a chamber or retaining head at the top portion 14 and a support or retaining flange at the bottom portion 16 that are configured to fixedly retain the coalescing media 20 in the separation chamber 10, eg, so that it does not move, rotate, etc.

[0082] The separation apparatus 10 may include or take the form of a residential hydro-magnetic, sediment and air separation apparatus, for example, which may be used in a residence, and may include a separator tank having a separator input I or inlet nozzle configured to receive a hydraulic fluid F, having a tank wall 12 configured to form a volume / chamber within a separator chamber 18 for processing the hydraulic fluid F; and having a separator output O or discharge nozzle configured to provide a processed fluid, for example, with Figure 1 to Figure 2 The consistency shown Fig.9A , Fig. 9B : Vertically aligned corrugated perforated sheets

[0083] Fig.9A and Fig. 9B A vertically aligned corrugated perforated sheet 22 is shown in the form of a vertically aligned wavy perforated sheet that may have peaks 22d, crowns 22e, and a surface 22f in between, and may be assembled to one another with the peaks 22d of one corrugation assembled to the crowns 22e of another corrugation. Alternatively, a series of vertically aligned corrugated perforated sheets 22 having peaks 22d and crowns 22e may be assembled to one another peak to peak and crown to crown. In other words, the scope of the present invention is not intended to be limited to any particular alignment of the peaks and crowns of the vertically aligned corrugated perforated sheets 22. Fig.9A and 9B In the embodiment of the present invention, each vertically aligned corrugated perforated sheet 22 has three (3) peaks 22d, four (4) crowns 22e and six (6) surfaces 22f in the middle. (Within the spirit of the present invention, the terms "peaks" and "crowns" can be used interchangeably.)

[0084] Vertically aligned perforated sheets

[0085] A series of vertically aligned corrugated perforated sheets 22 may have a plurality of openings or perforations 22b which provide multiple surfaces for dissolved gases and solids or particles to coalesce around. Fig.9A , Fig. 9B As shown, the plurality of openings or perforations 22b may be circular openings or perforations, and the plurality of surfaces may be circular or cylindrical surfaces, for example, so as to be uniformly configured on the vertically aligned corrugated perforated sheet 32. However, the scope of the present invention is intended to include, and contemplated embodiments include, within the spirit of the present invention, a plurality of openings or perforations 22b and a plurality of surfaces having shapes and surfaces of different types or kinds, for example, including triangles and surfaces, rectangles and surfaces, squares and surfaces, hexagons and surfaces, etc. In other words, the scope of the present invention is not intended to be limited to the shape of the openings or perforations 22b and their associated surfaces. For example, in one type of application, the plurality of openings or perforations 34 may have one shape and surface, while in another application, as will be understood by those skilled in the art, the plurality of openings or perforations 22b may have another shape or surface.

[0086] In addition, and by way of further example, and with Fig.9A , Fig. 9B As shown, multiple openings or perforations 22b can be configured or sized to have the same size, for example, so as to be evenly distributed on the vertically aligned corrugated perforated sheet 22. However, the scope of the present invention is intended to include, and embodiments of multiple openings or perforations 22b with different sizes included in the spirit of the present invention are contemplated. In addition, the scope of the present invention is not intended to be limited to the size of multiple openings or perforations 22b, for example, it can be configured or sized to a specific size based on a specific application, as will be understood by those skilled in the art. For example, in one type of application, multiple openings or perforations 22b can have one size or size, and in another application, multiple openings or perforations 22b can have another size or size.

[0087] In addition, and by way of further example, and with Fig.9A , Fig. 9B As shown, multiple openings or perforations 22b can be configured, sized or spaced apart relative to each other, with the same distance in the middle, for example, so as to be evenly distributed on the vertically aligned corrugated perforated sheet 22. However, the scope of the present invention is intended to include, and it is contemplated that embodiments of multiple openings or perforations 22b with different distances in the middle are included in the spirit of the present invention. In addition, the scope of the present invention is not intended to be limited to any specific distance in the middle of multiple openings or perforations 22b, for example, it can be configured or sized to have a specific distance in the middle based on a specific application, as will be understood by those skilled in the art. For example, in one type of application, multiple openings or perforations 22b can have a distance in the middle, and in another application, multiple openings or perforations 22b can have another and different distance in the middle.

[0088] A series of vertically aligned corrugated perforated sheets 22 may have angled corrugations that direct fluid through the coalescing media 20 where maximum surface contact occurs. Fig.9A and Fig. 9BAs shown, the vertically aligned corrugated perforated sheet 22 has angled corrugations at 90° angles (i.e., right angles). When the fluid has completed its passage through the coalescing media 20, the angled corrugations can direct the fluid to the separator output O to exit the coalescing removal separator 10 and allow the pressure drop to recover. However, the scope of the present invention is intended to include, and embodiments having angled corrugations of different angles are contemplated to be included within the spirit of the present invention. For example, the scope of the present invention is intended to include, and embodiments including angled corrugations greater than or less than 90° are contemplated, for example, so as to configure or size a particular angled corrugation based on a particular application, as will be understood by those skilled in the art. For example, in one type of application, the angled corrugations may have one angle, while in another application, the angled corrugations may have another and different angle.

[0089] Other related technologies of the assignee

[0090] This application also relates to patent application serial number 17 / 204,141 filed on May 17, 2021, and patent application serial number 17 / 518,698 filed on November 4, 2021, both of which are assigned to the assignee of this application, and both of which are hereby incorporated by reference in their entirety.

[0091] Scope of the Invention

[0092] The embodiments shown and described in detail herein are provided as examples only; and the scope of the present invention is not intended to be limited to the specific configurations, dimensions and / or design details of these parts or elements included herein. In other words, those skilled in the art will understand that design changes can be made to these embodiments and make the resulting embodiments different from the embodiments disclosed herein, but still within the overall spirit of the present invention.

[0093] It should be understood that any of the features, characteristics, alternatives or modifications described with respect to a particular embodiment herein may also be applied, used or combined with any other embodiment described herein, unless otherwise stated herein.

[0094] While the present invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein without departing from the spirit and scope of the present invention.

Claims

1. A separation device having a tank wall, a top portion and a bottom portion combined to form a separation chamber for processing a hydraulic fluid, the separation device comprising: a coalescing media comprising a vertically assembled perforated sheet having a surface with a plurality of openings, the vertically assembled perforated sheets being configured to form a coalescing media interior space in the separation chamber, and the vertically assembled perforated sheets being further configured and shaped to slow down the hydraulic fluid and enable entrained gas, ferromagnetic or ferrite particles and other solids to coalesce and emerge from the hydraulic fluid via a coalescing action caused by the hydraulic fluid contacting and flowing through the coalescing media; as well as A magnetic separation insert is connected to the bottom part of the separation device and arranged in the internal space of the agglomeration medium, the magnetic separation insert having a non-magnetic sleeve surrounding a removable magnet insert, the removable magnet insert being configured to generate a magnetic field to attract and collect the ferromagnetic or ferrite particles that are agglomerated on the non-magnetic sleeve and come out of the hydraulic fluid, and the removable magnet insert is also configured to be removed from the inside of the non-magnetic sleeve to release the ferromagnetic or ferrite particles attracted and collected on the non-magnetic sleeve, so that the released ferromagnetic or ferrite particles can fall to the bottom part of the separation chamber.

2. The separation device according to claim 1, wherein The separation device comprises a bottom coupling member arranged on the bottom portion of the separation device; and The non-magnetic sleeve includes a sleeve coupling member configured to be removably coupled to the bottom coupling member for coupling the magnetic separation insert to the bottom portion of the separation apparatus.

3. The separation apparatus of claim 2, wherein the non-magnetic sleeve comprises a non-magnetic surface configured to collect the ferromagnetic or ferrite particles attracted to the removable magnet insert by the magnetic field.

4. The separation device according to claim 2, wherein The removable magnet insert includes a handle having an insert coupling member; and The sleeve coupling member is configured to receive the insert coupling member and couple the removable magnet insert to the non-magnetic sleeve when the removable magnet insert is inserted into the non-magnetic sleeve.

5. The separation apparatus of claim 4, wherein the removable magnet insert comprises: a rod connected to the handle; as well as An alternating stack of magnets and spacers is configured to be slid onto the rod and retained by bolts fastened to the ends of the rod.

6. A separation apparatus according to claim 5, wherein the alternating stacks of magnets comprise opposing poles arranged such that like poles face each other and are separated by spacers.

7. The separation device according to claim 5, wherein the non-magnetic insert is made of stainless steel; or the spacer is made of carbon steel; or the non-magnetic insert is made of stainless steel and the spacer is made of carbon steel.

8. The separation apparatus of claim 1, wherein the vertically assembled perforated sheets are made of stainless steel.

9. A separation device according to claim 8, wherein the vertically assembled perforated sheets have vertical rhombuses, the vertical rhombuses have angled edges, the angled edges are configured to guide the hydraulic fluid through the coalescing medium and into the internal space of the coalescing medium, and the vertical rhombuses have reverse angled edges, the reverse angled edges are configured to guide the hydraulic fluid from the internal space of the coalescing medium to the outlet or discharge nozzle, leaving the separation chamber and allowing the pressure drop to recover.

10. The separation apparatus of claim 1, wherein the vertically assembled perforated sheet is configured as a corrugated sheet having peaks, crowns, and surfaces between the peaks and the crowns.

11. The separation apparatus according to claim 10, wherein the vertically assembled perforated sheets are formed and assembled from a single sheet having two ends coupled to form a rhombus, or are formed and assembled from a plurality of sheets having corresponding ends coupled to form the rhombus.

12. The separation apparatus of claim 1, wherein the coalescing media inner space is an open space that is 58% of the volume of a separator chamber or larger than the volume of the separator chamber to improve the pressure drop characteristics of the separation apparatus.

13. The separation device of claim 1, wherein the separation device comprises a well assembly at the bottom portion of the separation chamber, the well assembly being configured to collect the released ferromagnetic or ferrite particles.

14. The separation apparatus of claim 1, wherein the separation apparatus comprises a chamber head at the top portion and a support flange at the bottom portion, the chamber head and the support flange being configured to retain the coalescing media in the separation chamber.

15. The separation device of claim 1 , wherein the separation device comprises a maintenance indicator configured to respond to magnetic flux generated by the magnetic separation insert and to provide maintenance indicator signaling containing information regarding required maintenance on the separation device, including instances where the maintenance indicator signaling comprises audio signaling and / or visual signaling.

16. A separation device according to claim 15, wherein the maintenance indicator is configured to respond to the reduced magnetic flux when the released ferromagnetic or ferrite particles are removed from the bottom portion of the separation chamber, and provide corresponding maintenance indicator signaling containing information that no maintenance is required.

17. The separation device of claim 15, wherein the maintenance indicator comprises a circuit having a magnetic sensor configured to respond to the magnetic flux.

18. The separation device of claim 17, wherein the magnetic sensor comprises a reed switch or a Hall Effect sensor.

19. The separation device of claim 17, wherein the circuit includes a light configured to provide visual maintenance indicator signaling, including instances of the light turning on / off, flashing, or changing color.

20. The separation device of claim 17, wherein the magnetic sensor is configured to respond to the magnetic flux exceeding a desired magnetic flux threshold.

21. The separation apparatus of claim 20, wherein the desired magnetic threshold value is dependent upon and based upon the amount of ferromagnetic or ferrite particles attracted and collected onto the non-magnetic sleeve.

22. The separation apparatus of claim 1, wherein the separation apparatus comprises a residential hydro-magnetic, sediment and air separation apparatus, the residential hydro-magnetic, sediment and air separation apparatus comprising: a separator tank having a separator input or inlet nozzle configured to receive said hydraulic fluid, said separator tank having a tank wall configured to form a volume / chamber inside a separator chamber to process said hydraulic fluid, and said separator tank having a separator output or discharge nozzle configured to provide a processed hydraulic fluid having at least some of said entrained gas, said ferromagnetic or ferritic particles and said other solids removed.

23. The separation apparatus according to claim 1, wherein the separation apparatus comprises a drain valve configured at the bottom portion of the separation chamber to open and discharge the released ferromagnetic or ferrite particles.

24. The separation apparatus of claim 1, wherein the separation apparatus comprises a vent configured at the top portion of the separation chamber to exhaust the entrained gas out of the hydraulic fluid.

25. The separation apparatus of claim 1, wherein the plurality of openings formed in the surface of the vertically assembled perforated sheets also agglomerate the gas and the other solids in the hydraulic fluid.

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