Compressed Air Dryer Insert with Baffle and Drainage Channels
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Solution Overview
Problem
Compressed air drying apparatuses face challenges in achieving uniform air distribution and efficiently removing water droplets when space is limited, as conventional conical diffusers are too long and require additional filters with mechanical components that increase size and maintenance needs.
Innovation Solution
An insert with a baffle and supports having liquid drainage channels is used within the apparatus, disrupting air flow for uniform distribution and capturing water droplets, which then drain under gravity, eliminating the need for external filters and reducing apparatus size and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conical diffuser is used to create uniform air distribution from a small inlet to a large housing, then uniform air distribution is improved, but the housing length increases significantly (1-1.5 times the diameter of the housing)
Solution Approach 1:
The insert divides the flow distribution function into multiple elements: a baffle plate creates initial flow disruption and direction change, while multiple supports with channels distribute air uniformly across the housing cross-section. This segmented approach achieves uniform distribution without requiring a long conical diffuser.
Solution Approach 2:
Instead of using a long axial diffuser structure, the invention uses radial supports extending from the baffle to the housing wall, distributing air in the radial dimension. This transforms the flow distribution from an axial length-dependent process to a radial dimension process, significantly reducing housing length requirements.
2Object-affected harmful factors
If an externally mounted filter is used to remove water droplets before compressed air contacts desiccant material, then water droplet removal is improved, but the apparatus volume increases and maintenance requirements increase due to additional mechanical components
Solution Approach 1:
The invention merges the water droplet separation function with the existing insert structure that is already present in the housing. The baffle and supports with channels form an integrated water separation system, eliminating the need for a separate external filter and reducing overall apparatus volume.
Solution Approach 2:
The insert structure serves dual functions: it distributes air uniformly and simultaneously separates water droplets from the compressed air stream. This self-service approach eliminates the need for separate maintenance components like filter elements and drainage valves, reducing both volume and maintenance requirements.
3Object-affected harmful factors
If an externally mounted filter with drainage valve is used to remove water droplets, then water droplet removal is improved, but reliability decreases due to additional mechanical components that can malfunction
Solution Approach 1:
The insert provides passive water separation using only the baffle geometry and gravity-driven drainage through support channels. There are no moving parts, valves, or active components that could malfunction, significantly improving reliability compared to filtered systems with mechanical drainage valves.
Solution Approach 2:
The invention extracts the problematic mechanical drainage valve from the water removal system, replacing it with a simple gravity-driven channel system. This removes the failure point while maintaining effective water droplet removal capability.
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 achieves even air distribution across desiccant material, reduces apparatus size and maintenance, and enhances energy efficiency by minimizing pressure loss and eliminating the need for separate drainage valves, while effectively removing water droplets without damaging the desiccant material.
Implementation Method 1
a baffle for interrupting the flow of a stream of compressed air passing from an inlet in the housing and causing the stream of compressed gas to change direction
Implementation Method 2
the air coming from the compressor is generally very hot and saturated with water vapour. It is therefore passed through an after cooler to reduce its temperature. However, this after cooler whilst cooling the air results in the condensation of water droplets from the saturated water vapour
Implementation Method 3
a plurality of supports extending from said baffle to adjacent an internal surface of the housing of the apparatus, at least one support including a channel to allow liquid deposited in said baffle from said stream of gas to flow towards said internal surface
Implementation Method 4
at least one adsorbent material located in said housing between said inlet and said outlet for absorbing at least one component of said stream of compressed gas
Data Source
Figure 1
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Figure 4
AI summary
An insert for use in an apparatus for the treatment of compressed gas,particularly compressed air, is disclosed. The insert includes a baffle for interrupting the flow of a stream of compressed air passing from an inlet in a housing of a dryer and causing the stream of compressed gas to change direction. The insert also includes a plurality of supports extending from the baffle to adjacent an internal surface of the housing which include a channel to allow liquid deposited in the baffle to flow towards the housing's internal surface.