Concentric Preliminary Separator for Oil-Air Filtration
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Solution Overview
Problem
Existing spin-on filters for separating oil from gas streams are costly, voluminous, and inefficient due to their design, which does not allow for low-cost and compact solutions for preliminary separation.
Innovation Solution
A separation device with a preliminary separator element comprising a coalescing filter medium, such as a ring-shaped or hollow cylindrical nonwoven filter material, arranged concentrically to the main separator element, which reduces the amount of fluid reaching the main separator and enhances flow distribution, leading to increased separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a preliminary separator element with coalescing filter medium is used, then separation efficiency is improved, but device complexity increases
Solution Approach 1:
The preliminary separator element is nested concentrically within the main separator element, with the preliminary separator having a smaller diameter and being positioned radially inward. This nesting arrangement allows both separator elements to occupy the same axial space, improving separation efficiency without significantly increasing the overall device volume or complexity.
Solution Approach 2:
The separation function is divided into two segments: a preliminary separator element for initial fluid separation and a main separator element for final separation. This segmentation allows each element to be optimized for its specific function, with the preliminary separator handling bulk fluid removal and the main separator achieving high-efficiency separation, thereby improving overall manufacturing precision.
2Volume of stationary object
If the preliminary separator element is arranged concentrically to the main separator element, then volume is reduced, but manufacturing complexity increases
Solution Approach 1:
The preliminary separator element is positioned concentrically within the main separator element, creating a nested cylindrical structure. This arrangement minimizes the axial volume required for the separator assembly while maintaining effective separation area, as both elements utilize the same radial space efficiently.
Solution Approach 2:
The support structure for the preliminary separator element serves multiple functions: it provides mechanical support for the preliminary separator, maintains the concentric arrangement, and facilitates the radial flow path. This multi-functionality reduces the number of separate components needed, simplifying manufacturing despite the complex concentric geometry.
3Manufacturing precision
If coalescing filter medium is used in the preliminary separator element, then separation efficiency is improved, but flow resistance increases
Solution Approach 1:
The separation process is segmented into two stages with different flow resistance characteristics. The preliminary separator element with coalescing filter medium handles the first stage where high separation efficiency is prioritized and the gas stream still has sufficient pressure. The main separator element handles the second stage with lower flow resistance requirements, achieving the final separation with minimal energy loss.
Solution Approach 2:
The nested concentric arrangement allows the gas stream to flow radially through the preliminary separator element and then axially through the main separator element. This flow path optimization ensures that the higher flow resistance of the coalescing filter medium is encountered when the gas pressure is still high, while the main separator operates with lower pressure drop, balancing separation efficiency and energy 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 device achieves a higher degree of separation with reduced flow resistance and lower re-entrainment of separated fluid, resulting in increased overall performance and efficiency.
Implementation Method 1
at least one preliminary separator element (40) being arranged in the housing (16, 18) in the flow pass of the gas stream between the raw gas inlet (30) and the main separator element (22, 23), in particular consisting of a ring-shaped or hollow cylindrical coalescing filter medium
Data Source
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AI summary
A separation device (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 (22, 23) comprising at least one hollow cylindrical coalescing filter medium (23) for removing fluid, in particular oil, from the gas stream, and wherein the separation device (100, 100') comprises at least one preliminary separator element (40) being arranged in the housing (16, 18) in the flow pass of the gas stream between the raw gas inlet (30) and the main separator element (22, 23), in such way, that the separation device (100) is designed in a compact manner and is inexpensive and easy to manufacture.