Separator insert and separator having such a separator insert

Abstract

The invention relates to a separator insert (II) for separating a flowable suspension (Su) in a centrifugal field into at least two flowable phases (Lp, Hp) of different density, which separator insert forms a preassembled, exchangeable unit for insertion into a frame (I) of a separator and has at least the following: one or more components that do not rotate during operation; a rotor (2) that is rotatable about an axis of rotation (D) during operation, wherein the rotor (2) has a drum (3) that comprises one or more openings and is composed of an upper drum part (100) and a lower drum part (101), and wherein the drum (3) has a separating means that is arranged in the drum (3) and rotates with the drum (3), and a distributor, characterised in that at least two or more or all of the functional elements of the separator insert (II) are manufactured as a single-piece prefabricated unit, wherein these functional elements comprise at least the upper drum part or the lower drum part and at least the separating means.

Description

[0001] Separator insert and separator with such a separator insert

[0002] The invention relates to a separator insert for a separator according to the preamble of claim 1 and to a separator according to claim 20. The invention also relates to a method for manufacturing a separator insert.

[0003] Separators, as defined in this document, are used to separate a free-flowing suspension into phases of different densities in a centrifugal field. This separation can also be used, in particular, to concentrate a phase intended for recovery as a valuable product. In various applications, such as in the pharmaceutical or biotechnology sectors, cleaning traditionally used metal separators often requires complex steam sterilization.

[0004] Against this background, so-called single-use separators have been increasingly used in the pharmaceutical and biotechnology sectors for several years. A separator insert of this type is known from WO 2022 / 33954 A1. According to this document, the separator drum and the disc assembly are each designed as disposable plastic components (single-use technology, such as the single-use of pre-qualified plastic parts) and combined to form the replaceable separator insert, which is preferably disposed of after processing a batch of product.

[0005] The separator insert known from WO 2022 / 33954 A1 comprises, on the one hand, non-rotating parts such as a housing or a container. On the other hand, the separator insert also includes a rotating rotor within the housing, which is composed of several components. The rotor comprises a drum, which may preferably be composed of an upper drum section and a lower drum section. It further comprises a distributor and a disc assembly (consisting of individual separating discs), these components of the rotor being arranged within the drum. Virtually all parts of the separator insert, and in particular the rotor, are made of a plastic material or a plastic composite material (hereinafter referred to as plastic material). Additionally, according to the prior art, magnets, for example, may be inserted into the upper and lower drum sections as components not made of plastic.The non-rotating components of the separator insert known from WO 2022 / 33954 A1, such as the inlet, peeling disc or gripper, upper housing part, and lower housing part with their inlet and outlet connections, are preferably also made of plastic. The individually prefabricated components of the single-use separator insert are assembled, for example, partially with seals, and, if necessary, appropriately fastened to one another, which can be achieved, for example, by screwing, bonding, or welding. The components, and in particular the materials used to manufacture them, must generally be approved and certified for their respective applications, e.g., in biotechnology or pharmaceuticals. The joints and the gaps between the assembled components are also part of the approval process.It is therefore desirable to minimize the number of materials and components, as well as the number of joints and gaps, for such a single-use separator application.

[0006] It is known from the state of the art to manufacture certain components of a separator using additive manufacturing processes.

[0007] For example, US 2018 / 008990 A1 describes how individual components of a separator, such as a drum bottom, a drum top, a disc pack and an inlet / outlet unit, can be manufactured by additive manufacturing.

[0008] EP 2 352 598 B1 describes a one-piece disc pack for a separator, which can be manufactured, for example, as a precision casting component or as a plastic injection molding component.

[0009] Furthermore, it is known from DE 10 2015 117 375 A1 that the individual parts of a separator made of plastic can also be manufactured using 3D printing.

[0010] Furthermore, KR 470 008 641 A proposes that individual components of a separator can be manufactured by additive manufacturing.

[0011] The object of the invention is therefore to provide, starting from the prior art, a separator insert for a separator which has fewer individual parts and thus fewer joining points and gaps than the separator inserts manufactured according to the generic prior art.

[0012] This problem is solved by the object according to claim 1, i.e. by a separator insert for separating a flowable suspension in a centrifugal field into at least two flowable phases of different densities, which forms a pre-assembled, interchangeable unit for insertion into a frame of a separator and comprises at least the following: one or more components that do not rotate during operation and a rotor that is rotatable or rotating about an axis of rotation during operation, wherein the rotor has a rotatable drum that includes one or more openings and has a drum upper part and a drum lower part, wherein the drum has a separating agent arranged in the drum and rotating with the drum and a distributor.The separator insert is further characterized in that at least two or more or all functional elements of the rotor of the separator insert are manufactured as a single-piece prefabricated unit, wherein these functional elements comprise at least the upper drum part or the lower drum part and at least the separating agent. The invention also provides the separator of claim 22 and the method for manufacturing a separator insert according to claim 24.

[0013] In a particularly preferred embodiment, the one-piece prefabricated unit may be manufactured using an additive manufacturing process. Alternatively, it may be provided that, instead of additive manufacturing, another process is used, for example, a casting process – e.g., injection molding, thermoforming, or rapid liquid printing (RLP), or even machining, if the geometry of the unit permits.

[0014] The single-piece prefabricated unit, preferably manufactured using an additive manufacturing process, achieves a functional integration approach by not only producing individual components of the separator insert using additive manufacturing, which then need to be assembled, but also by producing a geometrically complex, single-piece prefabricated unit without joints in a single manufacturing process, which has the strength required for use in a separator or, in this case, a "separator insert".

[0015] This eliminates the assembly and joining steps typically required when the drum upper or lower section and the release agent are each designed as one or more separate parts and then joined together. This significantly simplifies drum manufacturing. The hygienic properties of the drum are also improved by the single-piece drum section, as the elimination of joints and sealing elements results in fewer crevices for potential contamination.

[0016] Optionally, using only a single material also simplifies the required sterilization of the insert with the one-piece unit, as only one suitable sterilization method needs to be found and implemented. Manufacturing the rotating drum of the separator from as few components as possible offers further advantages, such as a reduced risk of imbalance due to uneven component tolerances. Potential component misalignment, which can lead to undesirable gaps or channel narrowing, is also reduced by fewer components and even eliminated when manufactured from a single piece. The few remaining components can be joined, for example, by gluing, welding (laser or ultrasonic welding), or form-fitting. This eliminates the need for otherwise required seals and small assembly parts such as screws.The same material used for manufacturing the components can advantageously be used as the adhesive.

[0017] The term "additive manufacturing process" is defined in this document by ISO 529000. Section 3.1.2 of its 2021 edition defines "additive manufacturing (AM)" as follows: "process of joining materials to make parts from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing and formative manufacturing methodologies." "Additive manufacturing" as defined by this standard—and also as defined in this document—is therefore the general term for those technologies that successively join materials to create physical objects specified by 3D model data. 3D printing with plastic material is one such additive manufacturing process. Selective laser sintering (LSL) and stereolithography (LSA) have proven to be particularly suitable manufacturing processes for the separator application described here.These products are characterized by high strength despite their thinness. Products manufactured using stereolithography are distinguished by smooth surfaces and water resistance.

[0018] It is advantageous, simple, and cost-effective for single-use applications if the prefabricated, one-piece unit is made from a plastic material (including filaments) or a plastic composite material (including fiber-reinforced filaments). Polyamides (PA) and SLA resins are particularly suitable for this purpose.

[0019] For other applications, it may be advantageous if the one-piece prefabricated unit is made from a different material, such as metal or ceramic.

[0020] Further components – including parts that may not rotate during operation – can then be assembled with this one-piece prefabricated multifunctional unit to form the separator insert and preferably bonded together. To further reduce gaps and separate parts and to further increase functional integration, the one-piece prefabricated unit, which is preferably manufactured in one piece using an additive manufacturing process, can optionally also include a distributor shaft. Furthermore, in a further preferred embodiment, the distributor shaft of the one-piece prefabricated unit can optionally also have a distributor foot upper part at its lower axial end, and the one-piece prefabricated unit, which is preferably manufactured in one piece using an additive manufacturing process, can also include the distributor foot upper part.By further integrating one or more parts of the distributor into the one-piece manufactured unit, the number of joining points and the number of columns is reduced even further.

[0021] It can be particularly advantageous to provide that the diameter of the drum upper part and / or the drum lower part of the separator insert is greater than or equal to 50 mm and neither is equal to 100 mm. This is because, for drums with dimensions up to 100 mm, the manufacturing of one of the drum parts using additive manufacturing is particularly feasible. Accordingly, the separator manufactured in this way can preferably be used in batch operation with a batch size of less than 500 liters. A preferred application for the separator is in the field of cell separation from cell-containing suspensions in the pharmaceutical industry. The component manufactured according to the method of claim 1 can thus preferably be used for such a "small" drum with a "short" operating time (single batch) and, for example,It can be used for processing fermenter broths at a rather low g-number suitable for the cells, and can easily exhibit the strength required for use in such a separator.

[0022] It can be particularly advantageous for the release agent to be designed as a stack of separating plates with several axially stacked plates. Such a stack of separating plates can be manufactured surprisingly well as a single piece with the upper or lower drum section.

[0023] The one-piece manufacturing of the separator plate stack, and optionally also a distributor component, with the drum upper or lower section reduces the risk of imbalances. Furthermore, the reduced number of parts results in fewer assembly errors.

[0024] It can be particularly advantageous for the release agent to be designed as a stack of separating plates with several axially stacked plates. Such a stack of separating plates can be manufactured surprisingly well as a single piece with the upper or lower drum section. This advantage becomes especially apparent when the axial spacing of the separating plates, or the axial extent of the gap between the plates, is in the range of 0.2 to 2 mm.

[0025] Previously, it was necessary to provide the drum of a disc centrifuge with a separation point in order to mount internal components such as the distributor, the disc stack, or the peeling disc into the drum. According to the invention, a drum without a peeling disc can be manufactured entirely in one piece, consisting of the complete distributor (distributor shaft and distributor base), the separating disc stack, the drum upper section, and the drum lower section. A drum into which a peeling disc with a drain pipe projects, without being directly part of the drum, can also be manufactured in one piece according to the invention.

[0026] For this purpose, an additive manufacturing process is used, which allows such a "second" component, which protrudes into the first component, to be produced simultaneously. This peeling disc with drain pipe, manufactured at the same time as the complete drum, is then connected to the housing during subsequent assembly.

[0027] Alternatively, a functional element – ​​for example, a peeling disc with a drain pipe that does not rotate with the drum during operation – can be manufactured in a first manufacturing step, in order to then manufacture the complete remaining drum, which rotates during operation, around this functional element – ​​in particular the peeling disc – in a second manufacturing step using an additive manufacturing process.

[0028] According to a preferred optional embodiment, a functional element for driving and / or supporting the centrifuge can be integrated into the one-piece prefabricated unit, which is manufactured by an additive manufacturing process, in the area of ​​the upper or lower drum section. Thus, depending on the type of rotor drive, a receptacle for a magnetic element and / or a bearing ring or the like for driving and / or supporting the centrifuge can be integrated in the area of ​​the upper or lower drum section.

[0029] A functional element within the meaning of this document and the claims is one that contributes to, preferably substantially contributes to, the named function. For example, the separating agent serves to increase the clarification surface area. The distributor, on the other hand, serves to accelerate the suspension and introduce it into the separation chamber. Parts of these elements, such as separating plates or a distributor base (upper or lower part), are therefore exemplary functional elements. With regard to the drum, this applies in particular to the drum upper and lower parts. The integration of one or more further functional elements according to the characterizing element of claim 1, e.g., for the inlet or outlet of a suspension or phase, would also be conceivable. Likewise, there could be further functional elements that are integrated but serve functions not listed here.According to the characterizing feature of claim 1, functional elements for realizing various functions are preferably combined in one piece.

[0030] In a further advantageous embodiment, the separator insert may have a housing that is stationary during operation or rotates during operation, with the rotor arranged in the housing. Alternatively, the drum may be inserted, for example, into an outer drum or similar structure surrounding it within the frame.

[0031] The invention also provides the advantageous method of claim 24 for manufacturing a separator insert according to any related claim 1 to 21, in which at least two or more or all of the functional elements of the rotor of the separator insert II are manufactured as a one-piece prefabricated unit by an additive manufacturing process, wherein these functional elements comprise at least the upper part of the drum or the lower part of the drum and at least the separating agent.

[0032] It can optionally be advantageously provided that a functional element - for example, a peeling disc that does not rotate with the drum during operation and / or an associated drain pipe - is / are manufactured in a first manufacturing step, in order to then manufacture the complete remaining drum, which rotates during operation, using an additive manufacturing process around this functional element, in particular around the peeling disc, in a second manufacturing step.

[0033] And according to a further embodiment of the method, it may be provided that a further functional element or a further one-piece prefabricated unit, each comprising one or more further functional elements, is manufactured and provided and joined to the first one-piece prefabricated unit by gluing or welding or by positive locking.

[0034] Further advantageous embodiments of the invention can be found in the remaining dependent claims. The invention is described in more detail below with reference to several exemplary embodiments and the drawing. The invention is not limited to these exemplary embodiments, but can also be realized in other ways, either literally or equivalently. The drawing shows:

[0035] Figure 1: a schematic representation of a separator with a reusable frame and with a replaceable separator insert designed as a disposable or single-use separator insert, with hose sections arranged on it;

[0036] Figure 2: a schematic, cross-sectional representation of an interchangeable separator insert of a separator together with a schematic representation of an inlet and outlet system;

[0037] Figure 3: a schematic, cut-like representation of a section of the separator drum of the separator insert from Figure 2.

[0038] Several embodiments are described in the following figure description. Individual features of these embodiments can also be combined with embodiments not shown and are each suitable as advantageous embodiments of the objects described in one or more of the main and dependent claims.

[0039] The terms used below, such as "top", "bottom", "right", "left", "horizontal", "vertical", "radial", "axial", "inside" or "outside", refer to a separator in its usual operating position with a vertical axis of rotation. For other orientations in space, these directions must be transformed accordingly.

[0040] Fig. 1 shows an exemplary separator with a reusable frame I and an interchangeable separator insert II for the centrifugal separation of a product – a suspension Su – into different dense phases Hp, Lp. This separation can also be used to concentrate a phase to be recovered as a valuable product.

[0041] The separator insert II is preferably designed as an interchangeable, pre-assembled unit. In particular, the separator insert II is designed as a disposable separator insert that can be replaced as a whole and is constructed entirely or at least predominantly from one or more plastic or plastic composite materials. The frame I comprises a frame body 1-1. This may—but need not—be mounted on a carriage I-2 with rollers I-3. Brackets I-4 and I-5 may be provided on the frame body 1-1, which serve to receive and hold the separator insert II, even during operation.

[0042] The respective stator units 4b and 5b of the magnetic bearing devices 4 and 5 can be arranged in the respective consoles I-4 and I-5. The control and power electronics for this can be arranged in or on the frame I, e.g., in, on, or above the frame body 1-1.

[0043] One or both of the brackets I-4 and / or I-5 can be arranged laterally on the frame I, in particular on the frame body 1-1. It can be provided that, for example, the lower bracket I-5 is fixed to the frame body 1-1. It is then advantageous for the upper bracket I-4 to be height-adjustable on the frame body 1-1.

[0044] In this case, it is advantageous if the frame body 1-1 has such a vertical extension / length that the separator insert II is held in a fixed position by both height-adjustable consoles I-4 and I-5 in a first position, and is interchangeable in the other upper position. This can be achieved, for example, with a guide rail (not shown here) on the frame body 1-1 and a sliding guide carriage or slide (also not shown here) on the height-adjustable console I-4, which can be locked in a sliding position.

[0045] Preferably, a first, upper axial end of the separator insert II projects from below into or towards the upper console I-4, and a second, lower axial end of the separator insert II projects from above into or towards the other console I-5, whereby the separator insert II is held rotationally fixed to the frame body 1-1 and thus to the frame I.

[0046] Corresponding positive locking elements can be provided on the brackets I-4 and I-5 and on the housing 1 of the separator insert II, which does not rotate during operation of the separator, in order to insert the separator insert II in a rotationally fixed manner into the stator units 4b, 5b (see Fig. 1). The upper and lower stator units 4b, 5b can each have axes aligned with each other (see also Fig. 2). It is thus provided that the relative distance between the brackets I-4 and I-5 with the stator units 4b, 5b of the magnetic bearing assemblies 4 and 5 is adjustable in order to change the separator insert II, i.e., to remove a used separator insert II from the frame I and replace it with a new one.

[0047] It is further provided that the consoles I-4 and I-5 with the stator units 4a, 5a on the frame I can be moved axially apart and back towards each other in order to be able to change the separator insert II, as indicated by the corresponding arrows in Fig. 1.

[0048] Separator insert II is shown in Fig. 2. It can be disposed of after processing a batch of product and replaced with a new separator insert II.

[0049] According to the design shown in Fig. 1, the separator insert II of the separator comprises a housing 1 and a rotor 2 inserted into the housing 1, which is rotatable relative to the housing 1 during operation. The rotor 2 has an axis of rotation D. This can be oriented vertically, which corresponds to the design of the frame I (see Fig. 1). However, it can also be oriented differently in space if the frame I is designed accordingly.

[0050] The rotor 2 of the separator insert II has a rotatable drum 3. The rotor 2 is rotatably mounted at two locations axially spaced apart from each other in the direction of the axis of rotation D, each with its own magnetic bearing assembly 4, 5, which will be described in more detail below. Preferably, the rotor 2, and consequently the drum 3, is rotatably mounted at both axial ends. The separator insert II has rotor units 4a, 5a of the drive and magnetic bearing assemblies 4, 5. Stator units 4b, 5b of the magnetic bearing assemblies 4, 5, which are also shown in Fig. 2, are arranged on the frame I. The magnetic bearing assemblies 4, 5 preferably act radially and axially and hold the rotatably mounted rotor 2 suspended at a distance from the housing 1.

[0051] One or both of the magnetic bearing units 4, 5 are preferably also used as a drive device for rotating the rotor 2 with the drum 3 in the housing 1. In this case, the respective magnetic bearing unit 4, 5 forms a combined magnetic bearing and drive unit with which the rotor 2 is both axially and radially supported or suspended, and can also be set into a rotary motion. A preferred separator insert II – designed according to the invention as an example – is shown schematically in Fig. 2. In addition to the separator insert II, the stator units 4b, 5b of the magnetic bearing units 4, 5 are also shown schematically here.

[0052] The housing 1 is preferably made of a plastic or a plastic composite material. The housing 1 can be cylindrical and have a cylindrical outer shell, at the ends of which two radially extending boundary walls 6, 7 (lid and bottom) are formed. The housing 1 is designed in the manner of a container, which is advantageously hermetically sealed except for some openings / opening areas (to be discussed later).

[0053] The frame and separator insert could also be constructed differently than shown. For example, the separator insert could be motor-driven and have only a rotating drum but no non-rotating container.

[0054] The drum 3 serves for the centrifugal separation of a flowable suspension Su in the centrifugal field into at least two phases LP, HP of different densities, which can be, for example, a lighter liquid phase and a heavier solid phase or a heavy liquid phase.

[0055] In a preferred embodiment, the rotor 2 and its drum 3 have a vertical axis of rotation D. However, the housing 1 and the rotor 2 could also be oriented differently in space. The following description refers to the vertical orientation shown in Fig. 2. With a different orientation in space, the orientations change accordingly. In addition, one or both outlets may be arranged differently – to be discussed further below.

[0056] According to Fig. 2, one of the openings is formed in each of the two axial boundary walls 6, 7 – which are shown here as examples at the top and bottom – of the housing 1. One of the openings – in the first, here upper, axial boundary wall 6 – enables or serves, according to Fig. 2, as an inlet 8 for feeding a suspension Su, which is to be separated in the centrifugal field into at least two phases of different density – Lp and Hp – through the housing 1 into the drum 3. Here, the first phase is a lighter phase Lp and the second phase is a denser, heavier phase Hp compared to the first phase.

[0057] A second opening – in the second, here lower, axial boundary wall 7 – allows or serves as a drain 9 for the second, heavier phase Hp to flow directly from the drum 3 through the housing 1. The drum 3 has openings that correspond to or are associated with the openings of the housing 1. A feed pipe 11 for a suspension Su to be processed extends into an upper opening 10 at one axial end of the drum 3. This pipe passes through the housing 1, in particular through one of its – here upper – axial boundary walls 6.

[0058] The inlet pipe 11 is sealed to the housing 1 on its outer circumference, as shown in Fig. 2, and inserted into it – e.g., by welding or bonding – or it can optionally be integrally formed with the housing 1, for example, as an injection-molded plastic part. It is preferably also made of plastic. One end of the inlet pipe 1 protrudes outwards from the top of the housing 1 and extends through the upper boundary wall 6 into the drum 3, without touching the drum 3.

[0059] The inlet pipe 11, as shown in Fig. 2, passes concentrically to the axis of rotation D of the rotor 2 through the housing 1 and one, here upper, magnetic bearing 4, then extends axially further within the housing 1 into the rotatable drum 3 and ends there with its other end - a free outlet end.

[0060] The inlet pipe 11, as shown in Fig. 2, opens into a distributor 12 in the drum 3, which is rotatable with the drum 3. The distributor 12 has a tubular distributor shaft 13 and a distributor base 14. The distributor base has an upper distributor base part 14a and a lower distributor base part 14b. One or more distributor channels 15 are formed in the distributor base 14 between the upper distributor base part 14a and the lower distributor base part 14b. Separating agents – here designed as a stack of separating plates consisting of several conical separating plates 16 – can be placed on the distributor 12.

[0061] Furthermore, according to Fig. 2, a peeling disc 18 serves to drain the heavier phase Hp of the two phases Hp and Lp from the drum 3. A peeling disc shaft or a central drain pipe 19 penetrates the second axial boundary wall 7 (see Fig. 2). At its outer circumference, the drain pipe 19 is sealed to the housing 1 and inserted into it – e.g., by welding or bonding – or it can also be integrally formed with the housing 1, for example, as an injection-molded plastic part. It is preferably also made of plastic.

[0062] Drum 3 here has a drum lower part 101 and a drum upper part 100.

[0063] As shown in Fig. 2, the lower drum part 101 can have a lower cylindrical section 21 of smaller diameter, on / in which a substantially annular receptacle 33 for a rotor unit 5a of the lower magnetic bearing 5 is formed, which is inserted into this receptacle 33. The receptacle 33 can be closed by a receptacle cover 34.

[0064] This lower cylindrical section 21, of smaller diameter, is adjoined by a section 22 that widens conically from bottom to top. In the region of its largest diameter at the upper end, the lower part of the drum 101 may also have a radially outwardly projecting collar-like flange 24'.

[0065] The drum top 100 of the one-piece prefabricated unit also has a collar-like flange 24 – here at its lower end – and a tapered area (or a tapered section) 23 adjoining it upwards, and an upper cylindrical section 20 in which the rotor unit 4a of the upper magnetic bearing 4 is arranged in a receptacle 31. This receptacle 31 can be closed by an upper receptacle cover 32.

[0066] A separator-like area 17 is formed on the distributor foot 14b, which serves to divert a heavy phase from the actual separation chamber of the drum and to a peeling disc 18 that does not rotate during operation and projects into the drum 3.

[0067] Openings, which may be provided circumferentially distributed on the drum 3 (there may therefore be several openings on the drum 3), serve as outlets 25 of the light phase Lp from the drum 3.

[0068] An opening in the outer casing then allows the outlet or serves as a drain 26 of the lighter product phase Lp formed during centrifugal separation, which has been discharged from the drum 3.

[0069] The first outlets 25 on the radius ro of the drum 3 are designed as nozzle-like openings in the outer shell of the drum 3. They are also designed as so-called "free" outlets from the drum 3. These first outlets 25 serve to discharge the lighter phase Lp. The outlets 25 can be designed so that the lighter phase Lp exits radially, or alternatively, they can be shaped so that the lighter phase Lp exits tangentially against the direction of rotation of the drum 3, thus contributing to the drive of the rotor 2 and reducing the drive energy. This phase Lp exiting the drum 3 is collected in the housing 1 in an upper annular chamber 27. This upper annular chamber 27 is designed such that the phase collected in it is directed to the outlet 26 of the upper annular chamber 27. This can be achieved by placing the drain 26 at the lowest point of the upper trap ring chamber 27.The upper collecting ring chamber 27 is open radially inwards towards the rotating drum 3 and is spaced such that liquid exiting from the respective first outlet 25 during centrifugal separation essentially only exits into the associated upper collecting ring chamber 27, which is located at the same axial level.

[0070] Below the upper trap ring chamber 27, a chamber 28 not used for phase discharge can optionally be provided. This chamber 28 can optionally have a leakage drain 29, as shown in Fig. 2. The leakage can drain freely, preferably into a container. However, it can also be extracted by vacuum if the chamber 28 has a vacuum port for connecting a vacuum-generating device.

[0071] The upper trap ring chamber 27 and the chamber 28 can be separated from each other by a conical wall 30, which extends conically inwards and upwards from an outer shell of the housing 1 and ends radially in front of the drum 3, spaced apart on the inside.

[0072] Preferably at the lowest point of the upper trap ring chamber 27, the phase Lp is discharged from the housing 1 through the drain 26. Connections can be provided on the outside of the housing 1 in the area of ​​the drain 26 to allow for easy connection of cables, hoses, and the like. These connections can be integrally formed with the housing 1 or attached to it by adhesive bonding. The connections are preferably also made of plastic.

[0073] As the second outlet for the heavier phase Hp from the drum 3 through the housing 1, the peeling disc 18 is provided according to Fig. 2, which extends essentially radially and transitions into the axially extending central outlet pipe 19 in the manner of a peeling disc shaft, which penetrates the lower axial boundary wall 7 of the housing 1.

[0074] The skimming disc 18 serves to discharge the phase Hp in the manner of a centripetal pump. The skimming disc 18 can be arranged in a simple and compact manner in the drum 3 below the distributor 12 and below the disc stack. The radius ru corresponds to the radial immersion depth of the skimming disc 18 into the accumulating heavier phase Hp. The skimming disc 18 preferably remains stationary during operation.

[0075] The drain pipe 19 extends downwards from the housing 1, out of the drum 3, and through the lower boundary wall 7, without touching the drum 3. The drain pipe 19 can be formed integrally with the housing 1 or be sealed within it. A hose or similar component can be connected to the drain pipe 19 for drainage. The drain pipe 19 passes concentrically through the housing 1 and the lower magnetic bearing 5, perpendicular to the axis of rotation D of the rotor 2, and then extends axially within the housing 1 to the peeling disc 18.

[0076] Figure 3 shows that at least two or more functional elements of the separator insert II are manufactured together as a single, prefabricated unit – in particular by an additive manufacturing process. These functional elements comprise, firstly, the drum upper part 100 and at least the separating agent. The single, prefabricated unit is made of a plastic material or a plastic composite material.

[0077] As can be seen in Fig. 3, it is further advantageous and simple that the preferably one-piece prefabricated unit, which is produced by an additive manufacturing process, can also include a distributor shaft 13.

[0078] It can also be advantageously provided that the separating agent belonging to the preferably one-piece prefabricated unit has several axially arranged separating plates 16.

[0079] In addition, the recording 33 can be integrated into the drum top 100.

[0080] The preferably one-piece prefabricated unit made of a plastic material (also including filaments) or of a plastic composite material (also including fiber-reinforced filaments) has the flange 24 of the drum upper part 100, which serves as an joining aid. Further parts of the drum 3 or the rotor 2, such as the flange 24' of the drum lower part 101, can be easily and thus advantageously attached to the flange 24, for example by gluing or ultrasonic welding.

[0081] The upper cylindrical section 20 also has the outlets 25 for discharging the lighter phase Lp. The upper cylindrical section 20 further has an upper receptacle 31, which is designed to receive the rotor unit 4a of the upper magnetic bearing 4. The preferably one-piece prefabricated unit made of a plastic material or a plastic composite material further comprises the distributor shaft 13, which has a conical extension at its lower axial end for receiving the distributor base 14, as well as the separating element, which here is designed as a stack of separating plates consisting of several separating plates 16.

[0082] The prefabricated, one-piece unit made of a plastic material or a plastic composite material, designed in this way, has a number of advantages:

[0083] Not only are individual components of the separator insert II manufactured using additive manufacturing, which then have to be assembled, but a geometrically complex, ready-to-assemble module consisting of several functional elements without joining points is produced in a single manufacturing process.

[0084] The preferably one-piece prefabricated unit eliminates the assembly and joining steps that are usually required when the upper drum section 100 is assembled from individual parts. This significantly simplifies the manufacture of the drum 3.

[0085] The hygiene properties and sterilization of drum 3 are also improved by this unit, since the elimination or reduction of the joining points and sealing elements means that the one-piece manufactured unit has fewer gaps for possible contamination.

[0086] It is also conceivable to create several prefabricated, one-piece units, particularly through additive manufacturing or one of the other processes mentioned, such as casting, thermoforming, or rapid liquid pressure forming, and then join them together. These units are then joined, for example, by gluing or welding (laser or ultrasonic welding).

[0087] Furthermore, it is advantageous to use only a single material for all product-contacting components in order to simplify the process of approval and certification of the material for use, for example, in biotechnology or pharmaceuticals. Using only a single material also simplifies the required sterilization of the one-piece upper drum section 100, as only one suitable sterilization method needs to be found and implemented. The other components of the drum 3, such as a distributor foot base 14b and a joined drum lower section 101 (visible only in Fig. 2), are made of the same material and can, for example, be bonded to the one-piece unit at the flange 24 or welded using ultrasonic welding, after, for example,The peeling disc 18 – advantageously also made of the same material as the one-piece unit – was inserted into the lower part of the drum. The same material used for the manufacture of the components and assemblies can also be used as the adhesive.

[0088] The material for the one-piece manufactured drum top 100 could be, for example, a suitable resin (e.g., synthetic resin) commonly used in modern 3D printers and cured, for example, by UV light or laser. This can also be used for bonding. This ensures that only a single product-contacting material is used in separator insert II.

[0089] If the rotating drum 3 of the separator is manufactured from as few components as possible, further advantages arise, such as a reduced risk of imbalance due to one-sided accumulation of component tolerances, e.g., of the separating plates 16. A potential misalignment of components relative to one another, which can lead to undesirable gaps or the narrowing of channels (e.g., rising channels in the plate stack – not shown – or channels formed by the separating plate), is also reduced by fewer components and even avoided when manufactured from a single component. Assembly errors, such as the incorrect installation of separating plates 16, cannot occur.

[0090] By manufacturing the drum in one piece, which is then formed from the complete distributor 12 (distributor shaft and distributor base), the separator plate stack, the drum upper part 100 and the drum lower part 101, assembly errors and undesirable tolerances are reduced to a maximum.

[0091] By using adhesive, all otherwise required seals as well as all otherwise required small assembly parts such as screws are eliminated.

[0092] The two rotor units 4a, 5a of the magnetic bearing units 4, 5 are the only components of the separator insert II that are not made of plastic or synthetic resin. They are inserted into chambers 31, 33 in the lower drum section and the one-piece upper drum section 100, respectively, which are then tightly sealed with the resin (see Fig. 2). A method for manufacturing a separator insert II for separating a flowable suspension Su in a centrifugal field into at least two flowable phases Lp, Hp of different densities is also described. This insert forms a pre-assembled, interchangeable unit for insertion into a frame I of the separator and comprises at least the following functional elements: a housing 1 that is stationary during operation or rotates during operation, a rotor 2 arranged within the housing 1 and rotatable about an axis of rotation D during operation, the rotor comprising a drum 3.which comprises one or more openings and which is composed of a drum upper part and a drum lower part, and wherein the rotor 2 further comprises a separating agent arranged in the drum 3 and rotating with the drum 3, wherein the method comprises at least the following step: at least two or more of the functional elements of the rotor of the separator insert II are manufactured as a one-piece prefabricated unit by an additive manufacturing process, wherein these functional elements comprise at least the drum upper part 100 or the drum lower part 101 and at least the separating agent.

[0093] Reference symbol

[0094] frame

[0095] 1-1 Frame body

[0096] I-2 Car

[0097] I-3 roll

[0098] I-4 console

[0099] I-5 console

[0100] II Separator insert

[0101] 1 case

[0102] 2 Rotor

[0103] 3 Drum

[0104] 4, 5 magnetic bearing unit

[0105] 4a, 5a Rotor unit

[0106] 4b, 5b Stator unit

[0107] 6 upper boundary wall

[0108] 7 lower boundary wall

[0109] 8 Inlet

[0110] 9 Procedure

[0111] 10 Opening

[0112] 11 Inlet pipe

[0113] 12 distributors

[0114] 13 Distribution

[0115] 14 Distributor foot

[0116] 14a Distributor foot top

[0117] 14b Distributor base

[0118] 15 distribution channel

[0119] 16 separating plates

[0120] 17. septum-like area

[0121] 18 peeling discs

[0122] 19 drain pipe

[0123] 20 upper cylindrical section

[0124] 21 lower cylindrical section

[0125] 22 widening section

[0126] 23 tapered section

[0127] 24, 24' flange

[0128] 25 Outlet

[0129] 26 Expiry 27 Catching ring chamber

[0130] 28th Chamber

[0131] 29 Leakage process

[0132] 30 conical wall

[0133] 31 top shot

[0134] 32 upper recording cover

[0135] 33 lower image

[0136] 34 lower recording cover

[0137] 100 drum top

[0138] 101 Drum base

[0139] Su Suspension

[0140] Lp Light Phase

[0141] Hp Severe phase ro radius ru radius

[0142] D axis of rotation

Claims

Claims 1. Separator insert (II) for separating a flowable suspension (Su) in a centrifugal field into at least two flowable phases (Lp, Hp) of different densities, which forms a pre-assembled, interchangeable unit for insertion into a frame (I) of a separator and comprises at least the following: a) one or more components that do not rotate during operation, b) a rotor (2) that is rotatable about an axis of rotation (D) during operation, c) wherein the rotor (2) comprises a drum (3) which includes one or more openings and which has a drum top (100) and a drum top (101), and d) wherein the drum (3) comprises a separating agent arranged in the drum (3) and rotating with the drum (3) and a distributor, characterized in that e) at least two or more or all functional elements of the rotor are manufactured as a single-piece prefabricated unit,wherein these functional elements comprise at least the drum upper part (100) or the drum lower part (101) and at least the separating agent.

2. Separator insert (II) according to claim 1 , characterized in that the one-piece prefabricated unit is produced by an additive manufacturing process.

3. Separator insert (II) according to claim 1 , characterized in that the one-piece prefabricated unit is produced by a casting process or thermoforming or rapid liquid pressure (RLP).

4. Separator insert (II) according to claim 1 or 2 or 3, characterized in that the one-piece prefabricated unit is made of a plastic material or of a plastic composite material.

5. Separator insert (II) according to one of the preceding claims, characterized in that the separating agent of the one-piece prefabricated unit is designed as a stack of separating plates with several axially arranged separating plates (16).

6. Separator insert (II) according to claim 5, characterized in that the axial distance of the separating plates in the separating plate stack is in the range of 0.2 to 2 mm.

7. Separator insert (II) according to one of the preceding claims, characterized in that the diameter of the upper drum part and / or the lower drum part of the separator insert drum is greater than or equal to 50 mm and none is equal to 100 mm.

8. Separator insert (II) according to one of the preceding claims, characterized in that the one-piece prefabricated unit, which is manufactured one-piece by an additive manufacturing process, further comprises a distributor shaft (13).

9. Separator insert (II) according to one of the preceding claims, characterized in that the distributor shaft (13) of the one-piece prefabricated unit has a distributor foot upper part (14a) of a distributor foot (14) at its lower axial end and that the one-piece prefabricated unit, which is manufactured one-piece by an additive manufacturing process, further comprises the distributor foot upper part (14a).

10. Separator insert (II) according to one of the preceding claims, characterized in that the drum upper part (100) of the one-piece prefabricated unit has a lower flange (24) and a tapered area adjoining it upwards and an upper cylindrical section (20) in which a rotor unit (4a) of an upper magnetic bearing (4) is formed.

11. Separator insert (II) according to one of the preceding claims, characterized in that the drum lower part (101) has a lower cylindrical section (21) of smaller diameter, which has a lower annular receptacle (33) for a rotor unit (5a) of a lower magnetic bearing (5), wherein an axially upwardly widening section (22) adjoins this lower cylindrical section (21) of smaller diameter, which has a flange (24').

12. Separator insert (II) according to one of the preceding claims, characterized in that the flange (24') of the drum lower part (101 ) is attached to the flange (24) of the drum upper part (100).

13. Separator insert (II) according to one of the preceding claims, characterized in that a functional element for driving and / or supporting the centrifuge is integrated into the one-piece prefabricated unit, which is produced by an additive manufacturing process, in the area of ​​the upper part of the drum (100) or the lower part of the drum (101).

14. Separator insert (II) according to one of the preceding claims, characterized in that a receptacle for a magnetic element for driving and / or supporting the centrifuge is integrated into the one-piece prefabricated unit, which is produced by an additive manufacturing process, in the area of ​​the drum upper part (100) or the drum lower part (101).

15. Separator insert (II) according to one of the preceding claims, characterized in that the housing (1 ) is designed in the manner of a container which is designed to be closed except for one or more openings.

16. Separator insert (II) according to one of the preceding claims, characterized in that several openings are provided on the drum (3) which serve as outlets (25) of the light phase Lp from the drum (3).

17. Separator insert (II) according to one of the preceding claims, characterized in that a peeling disc (18) is arranged in the drum (3) below the distributor (12) and below the plate pack.

18. Separator insert (II) according to one of the preceding claims, characterized in that only a single product-contacting material is used in the separator insert II.

19. Separator insert (II) according to one of the preceding claims, characterized in that it has a housing (1) that is stationary during operation or rotates during operation, wherein the rotor (2) is arranged in the housing (1).

20. Separator insert (II) according to one of the preceding claims, characterized in that the separator insert (II) has at least two rotor units (4b, 5b) for magnetic bearing devices (4, 5) at two axially spaced locations of the drum (3), with which the rotor (2) can be suspended, rotatably mounted and set in rotation within the housing (I) during operation with the drum (3).

21. Separator insert (II) according to one of the preceding claims, characterized in that a further functional element or a further one-piece prefabricated unit, each comprising one or more further functional elements, is / are provided and is / are joined to the first one-piece prefabricated unit by gluing or welding.

22. Separator, characterized in that it has a frame (I) wherein an interchangeable separator insert (II) according to one of the preceding claims can be inserted into the frame (I).

23. Separator according to claim 22, characterized in that the housing (1 ) of the separator insert (II) and at least one of the consoles (I-4 and I-5) have corresponding positive locking means to hold the housing (1 ) rotationally fixed on the console (I-4 and I-5) so that the rotor (2) remains rotatable with the drum (3).

24. Method for manufacturing a separator insert according to any of claims 1 to 21 relating thereto, characterized in that at least two or more or all of the functional elements of the rotor of the separator insert II are manufactured as a one-piece prefabricated unit by an additive manufacturing process, wherein these functional elements comprise at least the upper part of the drum (100) or the lower part of the drum (101) and at least the separating agent.

25. Method according to claim 24, characterized in that a functional element - for example, a peeling disc (18) which does not rotate with the drum during operation and / or a drain pipe (19) associated with it - is / are manufactured in a first manufacturing step in order to then manufacture the complete remaining drum, which is rotatable during operation, in a second manufacturing step using an additive manufacturing process around this functional element, in particular around the peeling disc.

26. Method according to claim 24 or 25, characterized in that a further functional element or a further one-piece prefabricated unit, each comprising one or more further functional elements, is manufactured and provided and is joined to the first one-piece prefabricated unit by gluing or welding or positive locking.

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