Fiber-Membrane Separator Module Molding to Prevent Rotor Dislodging
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Solution Overview
Problem
The existing fiber-membrane separation modules in oil-gas separators are prone to dislodging and movement during high-speed rotation, affecting separation efficiency due to a lack of integral formation with the support framework.
Innovation Solution
A method involving injection molding to integrally form a fiber-membrane separation module, using a plastic framework and fiber-membrane cylinder, with clamping and retractable mechanisms to secure the fiber-membrane cylinder, ensuring it remains cylindrical and fixed during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fiber membrane is inserted into the support framework separately, then the manufacturing process is simple, but the fiber membrane is easy to fall out and move during high-speed rotation, affecting separation effect
Solution Approach 1:
The patent integrates the fiber membrane and support framework into a single integral structure through injection molding. The fiber membrane is pre-mounted on the support framework before molding, and the molten plastic penetrates and bonds with the fiber membrane, creating a unified structure that prevents dislodging while maintaining manufacturing efficiency.
Solution Approach 2:
The fiber membrane is pre-installed on the support framework before the injection molding process. This preliminary positioning ensures the fiber membrane is correctly placed and secured before the plastic material is injected, preventing any movement or misalignment during operation.
2Reliability
If the fiber membrane and support framework are integrally formed, then the separation effect is improved, but the molding quality and structural complexity increase
Solution Approach 1:
The injection mold structure employs nested components including an inner retractable mechanism within the outer mold cavity. The inner retractable mechanism can move inward to create space for demolding, while the outer mold maintains the overall shaping function, enabling complex integral molding with high precision.
Solution Approach 2:
The patent incorporates retractable mechanisms in the injection mold that can dynamically adjust during the molding and demolding processes. The inner retractable mechanism moves inward during demolding to release the fiber membrane, while remaining stationary during molding to maintain structural integrity, thus achieving both high molding quality and ease of demolding.
3Device complexity
If a conventional injection mold is used, then the device structure is simple, but the fiber membrane cannot be securely clamped and positioned during molding
Solution Approach 1:
The patent introduces sliding blocks as intermediary components between the mold and fiber membrane. These sliding blocks clamp the fiber membrane during molding and can move independently to facilitate demolding, acting as a mediator that secures positioning during manufacturing while enabling easy release afterward.
Solution Approach 2:
The injection mold is segmented into multiple independent components including outer mold, inner retractable mechanism, and sliding blocks. Each segment performs a specific function: the outer mold provides overall shaping, the inner mechanism handles demolding, and the sliding blocks secure positioning, allowing complex functionality without excessive overall complexity.
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
Ensures high-quality molding with a compact structure, preventing dislodging and deformation, thereby maintaining effective separation performance under high-speed conditions.
Implementation Method 1
the plurality of inward retractable blocks tighten an inner wall of the fiber-membrane cylinder
Implementation Method 2
at least two sliding blocks clamp the sewing portion on an outer side of the fiber-membrane cylinder
Implementation Method 3
an ejector sleeve is movably provided below the fiber-membrane cylinder and the plurality of sliding blocks; ejecting a fiber-membrane separation module by means of the ejector sleeve
Implementation Method 4
injecting molten plastic into the injection mold to form the plastic framework, wherein, the plastic framework and the fiber-membrane cylinder are integrally formed in an injection molding mode
Implementation Method 5
after cooling for a preset time, opening the injection mold
Data Source
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AI summary
Disclosed in the present invention is a method for manufacturing a fiber-membrane separation module for an oil-gas separator. The manufacturing method comprises: sewing fiber-membrane sheets into a fiber-membrane cylinder; disposing the fiber-membrane cylinder in an injection mold, wherein a plurality of inward retractable blocks tighten an inner wall of the fiber-membrane cylinder, at least two sliding blocks clamp a sewing portion on an outer side of the fiber-membrane cylinder, a plurality of sliding blocks are movably attached to an outer wall of the fiber-membrane cylinder, and an ejector sleeve is movably provided below the fiber-membrane cylinder and the plurality of sliding blocks; injecting molten plastic into the injection mold to form a plastic framework; and after cooling for a preset time, opening the injection mold, and ejecting a fiber-membrane separation module by means of the ejector sleeve.