Filter Insert Sealing for Liquid Separator Bypass
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Solution Overview
Problem
Existing filter inserts for liquid separators in compressed air systems face challenges in effectively sealing the clean side in relation to the raw side, especially when a bypass valve is activated, leading to potential leaks and reduced efficiency in oil separation.
Innovation Solution
A filter insert with a hollow-cylindrical separation element and an annular disk-shaped flange, featuring a seal element that is radially inwardly positioned relative to the bypass valve, ensuring effective sealing between the raw and clean sides. The seal element is designed for easy mounting and is pre-mounted on the flange, eliminating the need for complex O-ring sealing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a bypass valve is activated to relieve pressure, then pressure control is improved, but sealing reliability deteriorates due to potential leaks between raw and clean sides
Solution Approach 1:
The sealing system is segmented into multiple independent sealing elements: a first seal element at the flange interface and a second seal element at the bypass valve interface. This segmentation allows each seal to handle specific sealing tasks independently, ensuring that activation of the bypass valve does not compromise the seal between raw and clean sides.
Solution Approach 2:
The bypass valve is designed as an intermediary component with its own dedicated seal element. This intermediary sealing arrangement isolates the bypass function from the main sealing path, allowing pressure relief operation without creating leakage paths between the raw air inlet and clean air outlet sides.
2Reliability
If complex O-ring sealing systems are used to prevent leaks, then sealing reliability is improved, but device complexity and maintenance difficulty increase
Solution Approach 1:
The complex O-ring sealing system is extracted and replaced with simple, integrated seal elements that are built into the flange and bypass valve structures. The first seal element is integrated into the flange assembly, and the second seal element is integrated into the bypass valve, eliminating the need for separate O-rings and complex sealing mechanisms.
Solution Approach 2:
The sealing system uses simple, replaceable seal elements rather than complex, expensive O-ring systems. These simpler seal elements are easier to replace during maintenance, reducing both the cost and complexity of sealing system management.
3Ease of manufacture
If traditional flange sealing without integrated seals is used, then ease of manufacture is improved, but sealing reliability deteriorates leading to leaks
Solution Approach 1:
The sealing function is merged with the flange and bypass valve structures. The first seal element is combined with the flange assembly, and the second seal element is combined with the bypass valve, creating integrated components that provide both structural and sealing functions in a single manufacturing process.
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 proposed filter insert ensures reliable sealing of the clean side in relation to the raw side, even when the bypass valve is open, thereby preventing leaks and enhancing the efficiency of oil separation from compressed air. This design also simplifies maintenance and reduces costs by eliminating the need for complex O-ring sealing systems.
Implementation Method 1
a seal element, which is present at an end face so as to be oriented toward a radially inner side of the flange and which, in use as intended, arranged between the flange and the housing cover, seals a raw side of the separation element in relation to its clean side
Implementation Method 2
The at least one hollow-cylindrical separation element is configured as a hollow-cylindrical coalescer which coalesces the fine oil droplets to larger oil drops which settle due to the force of gravity in downward direction in the air/oil separation element and downstream thereof
Implementation Method 3
coalesces the fine oil droplets to larger oil drops which settle due to the force of gravity in downward direction
Data Source
AI summary
A filter insert for installation in a housing has a hollow-cylindrical separation element for separating liquid or aerosol from a gas flow by coalescence. The separation element has a central cutout. An annular disk-shaped flange is arranged at an end face of the separation element at the central cutout and can be arranged between a housing cover and a cylindrical housing body of the housing. A seal element is arranged at an end face of the flange so as to be oriented toward a radially inner side of the flange. The seal element, when the filter insert is in use as intended, is arranged between the flange and the housing cover and seals a raw side of the separation element in relation to a clean side of the separation element. A liquid separator provided with such a filter insert is used to separate oil from compressed air.