Compact Oil Separation Device Using Coalescing Filter Mat
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Solution Overview
Problem
Existing spin-on filters for separating oil from gas streams are costly, voluminous, and difficult to manufacture, with prior designs relying on complex geometries that increase production expenses and are not compact.
Innovation Solution
A separation device featuring a preliminary separator element with a coalescing filter medium, such as a fibrous nonwoven fabric, positioned between the housing cover and filter insert, which reduces the amount of fluid reaching the main separator element, allowing for a more uniform flow and increased separation efficiency, and is designed to be compact and inexpensive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex geometry is used for preliminary separation, then separation efficiency is improved, but production cost and device volume increase
Solution Approach 1:
The patent replaces complex, expensive preliminary separator geometries with a simple, disposable coalescing filter medium (mat or fabric) that can be easily manufactured and replaced. This filter medium performs the preliminary separation function through its material properties rather than complex geometry, significantly reducing production costs while maintaining separation efficiency.
Solution Approach 2:
The patent employs a coalescing filter medium with porous structure (mat or fabric) as the preliminary separator element. This porous material captures and coalesces liquid droplets from the gas stream through its pore structure, achieving effective preliminary separation without requiring complex geometric designs, thereby reducing both device complexity and production cost.
2Reliability
If a complex geometry is used for preliminary separation, then separation efficiency is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces complex, expensive preliminary separator geometries with a simple, disposable coalescing filter medium (mat or fabric) that can be easily manufactured and replaced. This filter medium performs the preliminary separation function through its material properties rather than complex geometry, significantly reducing production costs while maintaining separation efficiency.
Solution Approach 2:
The patent employs a coalescing filter medium with porous structure (mat or fabric) as the preliminary separator element. This porous material captures and coalesces liquid droplets from the gas stream through its pore structure, achieving effective preliminary separation without requiring complex geometric designs, thereby reducing both device complexity and production cost.
3Strength
If the housing cover is non-detachably connected, then structural integrity is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The patent divides the housing into separable segments (housing cover and housing corpus) that can be easily assembled and disassembled. The connection mechanism (such as bayonet coupling or threading) provides structural integrity when connected but allows for simple separation when needed, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The connection between housing cover and housing corpus transitions from static to dynamic - it provides rigid structural integrity during operation but allows for easy assembly and disassembly when needed. The connection mechanism enables the housing to adapt between these two states, maintaining strength during use while facilitating maintenance and filter replacement.
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 solution results in a more efficient separation device with a higher degree of separation, reduced fluid flow to the main separator, and lower production costs, achieved through the use of a compact and cost-effective design with a preliminary separator element that enhances fluid collection and flow distribution.
Implementation Method 1
at least one preliminary separator element (40), in particular at least one preliminary filter mat, arranged in the flow pass of the gas stream between the raw gas inlet (30) and the filter insert (20)
Implementation Method 2
A preliminary separator element with a coalescing filter medium, such as a fibrous nonwoven fabric, positioned between the housing cover and filter insert
Data Source
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AI summary
A separation device (100,100') for separating fluid from a gas stream deriving from a connecting device of a compressed air system or of a vacuum pump, the separation device (100,100') comprising a housing (16, 18) being designed to be replaceable connected with a connector head (200) of the connecting device, wherein a hollow cylindrical filter insert (20) is received in the housing (16, 18) in the flow pass of the gas stream between at least one raw gas inlet (30) and at least one clean gas outlet (32),wherein the housing (16, 18) comprises a cup-shaped housing corpus (18) and a housing cover (16) for covering a first axial end of the housing corpus (18), wherein the housing cover (16) is non-detachably connected to the housing corpus (18),wherein the filter insert (20) comprises at least one main separator element comprising at least one hollow cylindrical coalescing filter medium (23) comprising at least one coalescer material for removing fluid from the gas stream, and wherein in the flow pass of the gas stream between the raw gas inlet (30) and the filter insert (20) is arranged at least one preliminary separator element (40), in such way, that a preliminary separation of the gas stream having streamed into the housing (16, 18) by the raw gas inlet (30) is provided with low costs and low volume, it is proposed that the preliminary separator element (40) comprises at least one coalescing filter medium, comprising at least one coalescer material for removing fluid from the gas stream, the separation device (100,100') is designed in a compact manner and is inexpensive and easy to manufacture.