Capillary Filter System for Emulsion Oil Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter systems for removing undissolved oils, fats, and salts from water-containing emulsions used in machining processes are inefficient, leading to surface wetting that prevents oxygen exchange, causing bacterial growth and clogging, and requiring frequent machine cleaning and specialized disposal.
Innovation Solution
A filter system comprising a skimmer, emulsifier filter, adhesion filter, and capillary filter, using spherical polyamide filter elements with capillary action to mechanically, physically, and biologically treat emulsions, ensuring effective removal of oils, fats, and salts, and preventing bacterial growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface belt skimmers are used to remove floating oil/fat film, then oil removal is achieved, but the system becomes mechanically complex and requires continuous maintenance
Solution Approach 1:
The patent extracts the mechanical belt drive system and replaces it with a passive floating filter element system. The filter elements (18, 24, 38, 45) float on the emulsion surface and passively remove oil through capillary action, eliminating motors, belts, and complex mechanical components while maintaining oil removal effectiveness
Solution Approach 2:
The filter elements automatically float on the emulsion surface and self-regulate their position based on oil accumulation. The system requires no external power or mechanical actuation - the buoyancy of the filter elements and capillary forces in the porous material (16) provide self-service operation for continuous oil removal
2Stability of the object's composition
If emulsion is left standing for long periods, then oxygen exchange is prevented, but bacterial and fungal growth increases
Solution Approach 1:
The floating filter elements continuously remove oil from the emulsion surface, preventing the formation of a stable oil film that would block oxygen exchange. This continuous oil removal maintains emulsion stability while allowing periodic oxygen contact, preventing bacterial and fungal growth during extended standing periods
Solution Approach 2:
The system dynamically changes the oil film thickness parameter on the emulsion surface by continuously extracting oil. This parameter change maintains the oil content within a range that prevents excessive bacterial growth while preserving the lubricating function of the emulsion
3Reliability
If filter elements with high water absorption are used, then filtration effectiveness improves, but emulsion loss increases
Solution Approach 1:
The filter elements have localized high water absorption capacity (16) only in the regions where oil-water separation occurs. The porous material (16) is strategically positioned in the filter elements (18, 24, 38, 45) to capture oil through capillary action while the overall element design allows easy rinsing and recovery of emulsion, minimizing net emulsion loss
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
The system significantly reduces oil adhesion, prevents bacterial growth, minimizes emulsion consumption, and improves cooling performance by removing contaminants and reducing metal abrasion, thus extending tool life and maintaining coolant quality.
Implementation Method 1
with the base material for the plastic panels being polyamide, wherein the filter system comprises an inlet and an outlet
Implementation Method 2
A device and method for removing oil films is known from DE 4211123 C2. Here, the oil film is removed by adhesion when immersing a working body.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a filter system for removing and/or neutralizing undissolved oils, greases, and salts on/in water-containing emulsions from, in particular, tanks and baths that are used to hold and store emulsions, which are used to cool and lubricate workpieces and tools during machining, comprising at least one emulsifier filter, a downstream suction/pressure pump, a unit for gas enrichment, an adhesion filter having an automatic deaerator, a downstream oil-collecting vessel, and a capillary filter, wherein these are combined as a unit, such that the oil/grease film and the emulsion can be mechanically, chemically, and biologically treated.