Impactor Nozzle Chimney Assembly for Air-Oil Pre-Separation
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Solution Overview
Problem
Conventional air-oil separation assemblies suffer from high oil ingress through impactor nozzles due to ineffective pre-separation, leading to challenges in draining separated oil and increased packaging complexity and cost.
Innovation Solution
A separation assembly design featuring a nozzle plate with a chimney structure that prevents oil from entering the nozzles and a media holder that secures the filter media without penetrating, along with a pre-separator for enhanced separation, reducing oil carryover and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If restrictive pre-separation mechanisms are used to reduce oil entering impactor nozzles, then oil separation efficiency is improved, but fluid velocity increases causing oil particles to reach nozzles from adjacent surfaces
Solution Approach 1:
The housing is divided into a plenum chamber and an impactor chamber separated by a partition wall with openings. This segmentation allows the pre-separation to occur in the plenum chamber at lower velocities, while the impactor chamber handles the high-velocity impaction, resolving the contradiction between separation efficiency and fluid velocity.
Solution Approach 2:
The partition wall with openings acts as an intermediary between the plenum chamber and impactor chamber. It allows controlled fluid passage while maintaining distinct functional zones, enabling effective pre-separation without compromising the impaction process downstream.
2Reliability
If multiple separation components are added to the breather housing to achieve higher separation efficiency, then oil separation efficiency is improved, but packaging becomes more difficult and cost increases
Solution Approach 1:
The pre-separator and impactor are merged into a single integrated housing with distinct chambers. The partition wall with openings provides the necessary separation function while maintaining a compact, cost-effective single-unit construction, avoiding the need for multiple separate components.
Solution Approach 2:
The housing serves multiple functions: it acts as both the pre-separator body and the impactor housing, while the partition wall provides both structural support and flow control. This multi-functionality reduces the number of separate components needed, simplifying packaging and reducing cost.
3Strength
If the nozzle plate and filter media are welded into the housing, then assembly strength is improved, but assembly time increases and manufacturing complexity increases
Solution Approach 1:
Welding operations are replaced with a snap-fit mechanical assembly system. The nozzle plate and filter media are retained by clips or lugs that engage with corresponding features in the housing, providing sufficient strength without requiring thermal processing or specialized welding equipment.
Solution Approach 2:
The retention clips or lugs are designed to automatically engage and secure the nozzle plate and filter media during assembly, eliminating the need for manual welding operations. The design self-secures the components through simple insertion and engagement of the retention features.
4Reliability
If pins penetrate into the filter media to secure it in position, then retention reliability is improved, but filter media integrity is compromised and assembly complexity increases
Solution Approach 1:
Retention clips or lugs act as intermediaries between the housing and filter media, providing secure retention without direct penetration. These clips engage with the filter media edges or support structures, maintaining filter integrity while ensuring reliable retention.
Solution Approach 2:
The penetration function is extracted and replaced by external retention features. Instead of pins going through the filter media, retention clips engage with the filter media from the sides or support structures, eliminating the need for penetration while maintaining retention reliability.
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 chimney structure enhances oil separation efficiency, reduces assembly complexity, and lowers costs by minimizing oil ingress and eliminating the need for welding, while maintaining fluid flow efficiency.
Implementation Method 1
fluid flows radially beyond the outer surface of the at least one chimney in the housing between the inlet and the wall
Implementation Method 2
a pre-separator for enhanced separation
Implementation Method 3
air-oil separation assemblies with a nozzle plate, a large amount of oil enters through the impactor nozzles
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A separation assembly comprises a housing and a plate. The housing comprises an inlet and an outlet. The plate is positioned within the housing between the inlet and the outlet. The plate comprises a wall, at least one aperture, and at least one chimney comprising an inner surface surrounding the at least one aperture and an outer surface. The chimney extends from an upstream side of the wall and encompasses only a portion of a flow path between the inlet and the upstream side of the wall such that fluid can flow radially beyond the outer surface of the at least one chimney in the housing between the inlet and the wall.