Integrated Air-Oil Separator and Filter Block

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Solution Overview

Problem

Existing oil separation and filtration systems in air compressors suffer from high energy losses due to separate connections of oil filters and air-oil separators, leading to increased energy consumption, oil leakage, low pressure resistance, and environmental pollution from discarded components.

Innovation Solution

An integrated oil separation and filtration system where an air-oil separator and oil filter are connected on a single block, utilizing a thick housing with high compressive strength, a minimum pressure valve, and a temperature valve to reduce energy losses and facilitate compact design, with O-rings and handle wires for secure mounting, allowing for efficient separation and filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If oil filter and air-oil separator are connected separately, then each component can be independently maintained, but energy losses increase and system efficiency decreases

Engineering Contradiction:

ImproveIndependent maintenanceVSAvoidEnergy losses

Core Design Contradiction:

Ease of repairVSLoss of energy

Solution Approach 1:

The patent combines the oil filter and air-oil separator into a single integrated housing structure, allowing both components to function simultaneously in one unit. This merging eliminates the separate connections that caused energy losses while maintaining the ability to service both components together, resolving the contradiction between independent maintenance and energy efficiency.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If sleeve sheet is plastered to bottom plate in air-oil separator, then assembly is simplified, but oil leakage and low pressure resistance occur

Engineering Contradiction:

ImproveAssembly simplicityVSAvoidOil leakage prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the plastered sleeve sheet with a flexible membrane structure that can dynamically respond to pressure changes. This membrane design maintains simplicity in assembly while preventing oil leakage and withstanding pressure variations better than rigid plastered connections, resolving the contradiction between manufacturing ease and reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If oil filter and air-oil separator are used separately, then component selection is flexible, but material disposal increases and environmental pollution occurs

Engineering Contradiction:

ImproveComponent selection flexibilityVSAvoidMaterial disposal

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

By integrating the oil filter and air-oil separator into one unified system with a common housing, the patent reduces the total number of separate components that need to be manufactured, installed, and disposed of. This maintains functional versatility while minimizing material consumption and environmental pollution from discarded parts.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If thin housing is used in oil filter and air-oil separator, then manufacturing cost is reduced, but compressive strength and cycle time decrease

Engineering Contradiction:

ImproveManufacturing costVSAvoidCompressive strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs composite material construction for the housing, combining materials with different properties to achieve both cost-effectiveness and high compressive strength. The integrated housing uses material compositions that provide the necessary structural integrity for withstanding compression while keeping manufacturing costs reasonable, resolving the contradiction between manufacturing cost and strength.

Inventive Principle:

Principle #40Composite materials

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 system reduces energy losses, enhances compressive strength, minimizes material disposal, and reduces environmental pollution by integrating components for simultaneous operation and disposal, thus providing a more efficient and sustainable solution.

Implementation Method 1

an air-oil separator element (27) separating the oil droplets from the air

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Implementation Method 2

an oil filter element (10) that filters the particles contained in the oil

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS12023617B2Combined use of air-oil separator and oil filter in systems requiring oil separation and filtration

Publication Date: 2024.07.02 MIKROPOR MAKINA SANAYI VE TICARET ANONIM SIRKETI

AI summary

The present invention relates to operation of air-oil separators and oil filters used in systems requiring oil separation and filtration on a single block. In other words, the present invention discloses an oil separation and filtration system having an air-oil separator and an oil filter.