Centrifugal Separator Cyclone Cell Injection Molding
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Solution Overview
Problem
Conventional centrifugal separators for filtering combustion air in internal combustion engines require complex and costly manufacturing processes, especially when multiple units are arranged in parallel, leading to increased manufacturing expenditure and installation challenges.
Innovation Solution
A centrifugal separator design featuring a cyclone cell embedded by injection molding within a structural element of the housing, allowing for a simple two-part injection molding process and eliminating the need for complex fastening mechanisms, enabling the use of different materials for the cyclone cell and housing and facilitating the production of complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple cyclone cells are mounted in the housing using conventional fastening mechanisms, then the separation capacity is increased, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the mounting function with the housing structure itself by using the housing material as the fastening mechanism. The cyclone cells are embedded directly in the housing during injection molding, eliminating separate fastening components and reducing manufacturing complexity while maintaining the ability to accommodate multiple cyclone cells for increased separation capacity.
Solution Approach 2:
The housing material serves multiple functions: it provides the structural enclosure and simultaneously acts as the fastening mechanism for securing cyclone cells. This multi-functionality reduces the number of components needed and simplifies the manufacturing process while still enabling the housing to contain multiple cyclone cells for enhanced separation capacity.
2Reliability
If cyclone cells are securely mounted in the housing, then fluid-tight connections are achieved, but manufacturing costs increase
Solution Approach 1:
The housing material combines the structural function with the sealing function. By embedding cyclone cells directly in the housing during injection molding, the same material that provides structural support also creates fluid-tight connections, eliminating the need for separate sealing components and reducing manufacturing costs while maintaining reliability.
Solution Approach 2:
The housing material performs the sealing function for itself by being molded around the cyclone cells during the injection molding process. The material automatically forms fluid-tight connections as it is injected and cured, eliminating the need for additional sealing operations or components, thereby reducing manufacturing complexity and cost while ensuring reliable fluid-tight connections.
3Strength
If complex fastening mechanisms are used to secure cyclone cells, then secure mounting is achieved, but manufacturing expenditure increases
Solution Approach 1:
The patent extracts the fastening function from separate mechanical components and integrates it into the housing material itself. By using the housing material as the fastening mechanism through direct embedding during injection molding, complex fastening mechanisms are eliminated while maintaining secure mounting, thereby reducing manufacturing expenditure.
Solution Approach 2:
The patent replaces mechanical fastening systems (such as bolts, clips, or interlocking mechanisms) with a material-based embedding approach. The housing material itself provides the securing action through the injection molding process, substituting complex mechanical fastening systems with a simpler, more cost-effective material integration method that maintains mounting security.
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 approach reduces manufacturing costs and complexity, enabling efficient production of centrifugal separators with improved fluid-tight connections and adjustable separation degrees, while allowing for flexible material selection and vibration damping, thus enhancing the performance and cost-effectiveness of the filtration system.
Implementation Method 1
A fluid flowing into a centrifugal separator is guided such that centrifugal forces accelerate the particles that are to be separated from the fluid in a preferential direction
Implementation Method 2
For producing the centrifugal forces, guide vanes are usually used to generate a swirl within the separator housing
Implementation Method 3
The cyclone cell is embedded by injection molding in the structural element with form fit
Data Source
AI summary
A centrifugal separator for separating particles from a fluid has a housing with a structural element provided with an opening. A cyclone cell having an inflow opening and an outflow opening is provided and is adapted to produce a swirl in a fluid that is flowing in through the inflow opening and exits through the outflow opening. The cyclone cell is secured in the opening of the structural element by being form-fittingly embedded by injection molding in the structural element. In a method for producing the centrifugal separator, at least one cyclone cell is provided and is embedded by injection molding so as to form the structural element that secures at least one cyclone cell in the housing.