Roll-Formed Mist Eliminator Vanes With Rounded Separation Zones
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Solution Overview
Problem
Existing mist eliminator profiles are time-consuming and cost-intensive to produce due to the need for multiple individual work steps in forming separation zones with structures like projections and collection pockets.
Innovation Solution
The use of roll forming to produce embossed portions that serve as separation zones in mist eliminator profiles, replacing traditional sharp edges with round embossed portions for easier production and effective phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional bending, kinking, pressing, or welding methods are used to form separation zone structures, then the structures can be produced with defined geometries, but the production process becomes time-consuming and cost-intensive due to multiple individual work steps
Solution Approach 1:
The patent combines multiple individual work steps (bending, kinking, pressing, welding) into a single roll forming process. The roll forming machine performs all necessary deformations in one continuous operation, eliminating the need for separate operations and significantly improving both production simplicity and speed.
Solution Approach 2:
The roll forming process performs preliminary shaping of the metal sheet into the final profile geometry with integrated separation zone structures before any subsequent operations. The embossed portions are formed during the initial rolling process, eliminating the need for later forming operations.
2Ease of manufacture
If multiple individual work steps are used for producing mist eliminator profiles, then separation zone structures can be formed, but production costs increase
Solution Approach 1:
The patent merges multiple production operations into a single roll forming process. The complex separation zone structures that would require multiple discrete operations are instead created through a unified roll forming process with integrated tooling, reducing both process complexity and cost.
Solution Approach 2:
The roll forming machine serves multiple functions: it bends, embosses, and forms the complete profile geometry in one pass. This multi-functional approach replaces several specialized operations, simplifying the production process and reducing overall complexity.
3Shape
If sharp edges are used in vane profiles, then directional changes can be achieved, but the risk of contamination increases and cleaning becomes more difficult
Solution Approach 1:
The patent replaces sharp edges with rounded embossed portions in the vane profile. These curved features maintain the necessary directional changes in the profile while eliminating sharp corners that trap contaminants, thereby reducing contamination risk and facilitating easier cleaning.
Solution Approach 2:
The patent changes the geometric parameters of the profile edges from sharp (zero radius) to rounded (finite radius). This parameter change maintains the functional geometry while improving hygienic properties and reducing contamination accumulation.
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 approach simplifies and accelerates the production of mist eliminator profiles while maintaining effective phase separation, reducing production costs and minimizing the risk of contamination.
Implementation Method 1
During roll forming (also cold rolling of profiles), an originally planar sheet metal strip, for example, is led through multiple driven pairs of rollers arranged one behind the other until said strip has been bent into the desired profile shape.
Implementation Method 2
the separation zone has at least one embossed portion produced by roll forming... meet the requirements with regard to effective phase separation
Data Source
AI summary
A mist eliminator profile includes a plurality of vane profiles arranged in parallel with one another and at a distance from one another and at least one separation zone. The separation zone includes a plurality of embossed portions and is configured for removing liquid droplets from a gas flowing along the vane profile. The plurality of embossed portions are produced by a roll forming procedure and the direction of the vane profile changes direction after at least one of the embossed portions. The plurality of embossed portions include a rounded shape so that all directional changes of the vane profile are formed by one of the plurality of embossed portions.