Emulsion Filtration System with Spherical Elements
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Solution Overview
Problem
Existing filter systems for removing undissolved oils, greases, and salts from water-containing emulsions in containers and tanks used for machining operations are inefficient, leading to level gradients, overflow, and reduced emulsion recirculation due to the presence of track oils and metal debris.
Innovation Solution
A filter system comprising a skimmer for emulsion extraction, a three-way valve for vacuum control, spherical filter elements in multiple containers for mechanical, chemical, and biological treatment, and a capillary filter for final purification, which reduces vacuum requirements, prevents vortex formation, and ensures efficient emulsion recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If track oil is continuously dosed between slide rails to ensure good sliding, then lubrication performance is improved, but oil accumulates on the emulsion surface forming an oil-grease film that impedes emulsion outflow
Solution Approach 1:
The patent extracts and removes the harmful oil-grease film from the emulsion surface using a skimmer device with a suction pump. The skimmer continuously removes accumulated track oil and grease from the emulsion surface, preventing the oil film from impeding emulsion outflow while allowing continuous dosing of lubricant to maintain sliding performance.
Solution Approach 2:
The patent introduces an intermediary filtering system between the emulsion tank and the machining area. The filter system with spherical filter elements and capillary filters acts as a mediator that separates and removes oil-grease accumulations from the emulsion, allowing the emulsion to continue circulating effectively without being blocked by oil films.
2Reliability
If perforated screens are used to separate metal chips from emulsion, then pump protection is improved, but track oil impedes emulsion flow causing level gradient and overflow
Solution Approach 1:
The patent uses porous spherical filter elements made of sintered metal or plastic materials with specific pore structures. These porous filters allow emulsion to pass through while trapping metal chips and oil-grease accumulations, providing both pump protection and maintaining emulsion flow without the level gradient problems caused by traditional screens.
Solution Approach 2:
The patent changes the filtration approach from flat perforated screens to three-dimensional spherical filter elements with optimized pore parameters. This structural parameter change increases the effective filtering area and improves emulsion flow characteristics, preventing overflow while protecting the pump from metal chips.
3Manufacturing precision
If multiple filter containers are used for mechanical, chemical, and biological treatment, then purification effectiveness is improved, but system complexity increases
Solution Approach 1:
The patent combines multiple filtration functions into an integrated system. The spherical filter elements perform mechanical filtration, while the capillary filters handle both mechanical and biological purification. The system merges these functions in a compact arrangement that achieves high purification effectiveness without excessive complexity.
Solution Approach 2:
The spherical filter elements serve multiple functions simultaneously: they act as mechanical filters for metal chips, provide surface area for biological degradation of oils and greases, and maintain emulsion flow. This multi-functionality reduces the need for separate specialized components, simplifying the overall system structure while maintaining high purification effectiveness.
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 filter system effectively removes undissolved oils, greases, and salts, reduces level fluctuations, prevents overflow, and ensures continuous emulsion recirculation, thereby improving the efficiency and stability of machining operations.
Implementation Method 1
a device for sucking the emulsion out of the emulsion tank/container
Implementation Method 2
a three-way valve, wherein the inlet of the three-way valve is connected to the pump, the first three-way outlet is connected to the first filter container, and the second three-way outlet is connected to the second filter container
Implementation Method 3
first filter container, a second filter container, a third filter container, wherein the first filter container and/or the second filter container and/or the third filter container respectively have a removable screen insert, in which a plurality of spherical filter elements is located
Implementation Method 4
a capillary filter for final purification
Implementation Method 5
a pump connected to the outlet
Data Source
AI summary
The invention relates to a filter system for removing and/or neutralizing undissolved oils, greases and salts, preferably also floating bodies, such as metal debris, on/in water-containing emulsions from, in particular, containers and tanks that are used for holding and storing emulsions.