Frustum Separation Disk for Compact Oil Separator
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Solution Overview
Problem
Existing oil separators face challenges in miniaturization while maintaining separation efficiency, as increasing the number of stacked separation disks heightens the device, and reducing disk thickness compromises rigidity and separation efficiency.
Innovation Solution
The oil separator employs separation disks with inclined inner and outer peripheral parts forming frustums of cones or pyramids, allowing for increased surface area without lengthening the disk diameter, reducing height, and enhancing rigidity through bending and chamfering, enabling more disks to be stacked at a limited height with improved gas flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of stacked separation disks is increased to improve separation efficiency, then the height of the oil separator increases, making miniaturization difficult
Solution Approach 1:
The separation disks transition from a flat plate structure to a three-dimensional frustum structure with inclined inner and outer peripheral parts. This dimensional change allows the disks to stack more efficiently in the axial direction, increasing the number of disks that can be stacked within a limited height while maintaining separation efficiency.
Solution Approach 2:
The invention changes the geometric parameters of the separation disks by introducing inclination angles for the inner and outer peripheral parts. By optimizing these inclination angles, the disk thickness can be reduced while maintaining rigidity, allowing more disks to be stacked within the same height constraint.
2Length of stationary object
If the separation disks are thinned to reduce height, then rigidity deteriorates and separation efficiency decreases
Solution Approach 1:
The separation disks employ curved frustum surfaces with specific inclination angles instead of flat plates. This curvature provides structural rigidity while reducing material thickness, as the geometric shape itself contributes to strength rather than relying solely on material thickness.
Solution Approach 2:
The invention creates a composite structural form by combining the frustum shape with specific inclination angles, where the geometric configuration works together with the material to achieve both thinness and rigidity. The bent shape at the corner portion between inner and outer peripheral parts further enhances this composite effect.
3Ease of operation
If the inclination angle of separation disks is reduced to facilitate stacking, then centrifugal force transmission decreases and separation efficiency deteriorates
Solution Approach 1:
The invention applies different inclination angles to different parts of the separation disk: the inner peripheral part has one inclination angle optimized for centrifugal force transmission, while the outer peripheral part has another inclination angle optimized for stacking. This local differentiation allows each part to fulfill its specific function optimally.
Solution Approach 2:
By introducing the frustum shape with dual inclination angles, the invention adds dimensional complexity that enables simultaneous optimization of conflicting functions: the inner peripheral inclination maintains centrifugal force transmission efficiency while the outer peripheral inclination facilitates stacking.
4Length of stationary object
If the number of stacked separation disks is reduced to decrease height, then separation efficiency deteriorates and gas flow resistance increases
Solution Approach 1:
The frustum shape with inclined peripheral parts utilizes the axial dimension more effectively, allowing more disks to be stacked within the same height limit. This dimensional optimization increases the total surface area available for separation without increasing the overall height.
Solution Approach 2:
By changing the geometric parameters (inclination angles of inner and outer peripheral parts), the invention reduces the effective height occupied by each disk, enabling a higher number of disks to be stacked within the same space constraint.
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 design allows for a compact oil separator with increased separation efficiency and reduced gas flow resistance, maintaining high separation performance even with a larger number of stacked disks.
Implementation Method 1
when processing-target gas flows in clearances between the separation disks from inside the rotating separation disks, mist oil contained in the processing-target gas aggregates on surfaces of the separation disks due to centrifugal force
Data Source
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AI summary
An object of the present invention is to ensure designing a compact oil separator by reducing the height of stacked separation disks even if the number of stacked separation disks increases, and to avoid deterioration of separation efficiency. An oil separator 2 that separates mist oil from processing-target gas containing mist liquid includes a plurality of separation disks 63. The plurality of separation disks 63 rotate around an axis, and are stacked and spaced in an axial direction. The separation disk 63 includes an inner peripheral part 65 and an outer peripheral part 64. The inner peripheral part 65 forms a surface of a frustum of a hypothetical cone or pyramid coaxial with the separation disk 63, and is inclined with respect to a radial direction toward one side in an axial direction. The outer peripheral part 64 forms a surface of a frustum of a hypothetical cone or pyramid coaxial with the separation disk 63, and continuously extends outward from an outer peripheral edge of the inner peripheral part 65. The outer peripheral part 64 is inclined with respect to the radial direction toward another side in the axial direction.