Baffle Plate Droplet Separator for HVAC Airflow

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing droplet separators in air-conditioning, cooling, and ventilation systems suffer from incomplete droplet capture due to temperature gradients and thermal conduction, leading to re-condensation and entrainment of droplets, which can damage downstream components and require additional space and costs for improved separation efficiency.

Innovation Solution

A baffle plate is positioned directly behind the lamellae, inclined and with a lower edge closer to the droplet separator, having a height less than half the separator's height, and featuring a large number of horizontal slots for enhanced droplet capture with minimal space and cost impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a second layer of lamellae forming a package is arranged in the air flow behind the lamellar layer to achieve higher separation efficiency, then droplet separation efficiency is improved, but space requirements increase, manufacturing costs increase, and pressure losses increase

Engineering Contradiction:

Improvedroplet separation efficiencyVSAvoidspace requirements

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The droplet separator is divided into two functional zones: a front lamellar layer for initial droplet capture and a rear baffle plate for catching remaining droplets. This segmentation allows each component to be optimized for its specific function, achieving high separation efficiency without requiring a second full lamellar package

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The baffle plate extracts and performs the specific function of catching droplets that pass through or form on the rear side of the lamellar layer. By taking out this specific function from the lamellar structure, the design avoids the need for a complete second lamellar package, reducing space and cost while maintaining effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

Engineering Contradiction:

Improvedroplet separation efficiencyVSAvoidmanufacturing and assembly costs

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The baffle plate is a simple, inexpensive component compared to a full lamellar package. It can be manufactured as a single piece or simple assembly, requiring minimal materials and processing. This disposable-like simplicity in design dramatically reduces manufacturing and assembly costs while still achieving the necessary droplet capture function

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

Engineering Contradiction:

Improvedroplet separation efficiencyVSAvoidpressure losses

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The baffle plate is positioned specifically in the lower region where temperature-induced droplet formation occurs. This local placement targets the specific problem area without creating flow resistance throughout the entire separator, minimizing pressure losses while effectively addressing droplet separation in the critical zone

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration achieves nearly 100% droplet separation with reduced air resistance and minimal space requirements, preventing droplet entrainment and protecting downstream components.

Implementation Method 1

at least one baffle plate (3) is arranged directly behind the lamellae in the direction of flow, on which the droplets of the air stream hit in order to slide down the baffle plate

Methodology Applied

Scientific EffectImpact: Impact Force

Implementation Method 2

the baffle plate is inclined in relation to the droplet separator in such a way that its lower edge is closer to the droplet separator than its upper edge

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 3

Due to thermal conduction in the lamellae, this leads to renewed condensation on the rear side of the separator, in particular on the rear side of the lamellae

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

due to temperature layers in the air after the cooler, a temperature distribution occurs at the separator

Methodology Applied

Scientific EffectTemperature gradient: Temperature Gradient

Data Source

PatentEP2878353B1Droplet separator

Publication Date: 2019.11.13 FLAEKTGROUP DEUT GMBH

Figure 1~2
Figure 3~4
Figure 5

AI summary

The invention relates to a device for separating droplets from the airflow behind an air conditioning, cooling and/or ventilation unit, with several droplet-catching lamellae arranged parallel to each other, between which the air flows, wherein at least one baffle plate is arranged directly behind the droplet separator, in particular its lamellae, in the direction of flow, onto which the droplets of the airflow hit in order to slide downwards on the baffle plate.