Oil Mist Separator with Gas Channels and Impact Surface
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Solution Overview
Problem
Existing oil mist separators for internal combustion engines face challenges in efficiently separating fine oil particles, leading to incomplete de-oiling and potential engine malfunctions, and require complex structures with moving parts that are prone to wear and increased maintenance needs.
Innovation Solution
The oil mist separator employs a diffusion separator body with continuous free gas channels and an impact separation surface, allowing for high-efficiency diffusion separation of fine oil particles, with the gas flow shifting to impact separation as the diffusion body becomes loaded, maintaining separation efficiency over long periods without excessive pressure buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coalescer filter is used to separate oil particles from crankcase ventilation gas, then oil separation efficiency is improved, but the flow resistance increases over time due to clogging, requiring additional valves and increasing device complexity
Solution Approach 1:
The separator body is divided into multiple sections with different separation mechanisms: a first section with a coalescer filter for initial oil particle separation, and a second section with an inertial collector for further separation. This segmentation allows each section to handle specific separation tasks, maintaining efficiency while distributing the loading and extending service life.
Solution Approach 2:
The system dynamically adapts its separation mechanism based on operating conditions. As the coalescer filter becomes loaded, the flow naturally shifts toward the inertial collection mechanism in the second section. This dynamic behavior allows the system to maintain separation efficiency without requiring complex control valves or switching mechanisms.
2Manufacturing precision
If a coalescer filter is used to separate oil particles, then oil separation efficiency is improved, but the flow resistance increases over time, requiring a bypass valve that may release uncleaned gases
Solution Approach 1:
The separator is segmented into a first section with a coalescer filter and a second section with an inertial collector. This segmentation ensures that even when the coalescer filter becomes loaded, the second section continues to provide effective oil separation through inertial collection, preventing the release of uncleaned gases.
Solution Approach 2:
The inertial collector in the second section acts as a backup separation mechanism that is always available. Before the coalescer filter becomes completely blocked, the inertial collector continues to capture oil particles, providing a cushion against complete system failure and ensuring continuous reliable operation.
3Manufacturing precision
If a flow filter is added after an impact separator to capture remaining oil particles, then oil separation efficiency is improved, but the flow filter becomes completely blocked over time, requiring maintenance
Solution Approach 1:
The separation system is segmented into two main sections: a first section with a coalescer filter for initial separation and a second section with an inertial collector for further separation. This segmentation distributes the separation load and prevents any single filter from becoming completely blocked, thereby extending service life.
Solution Approach 2:
Different separation mechanisms are applied in different sections of the separator. The coalescer filter in the first section handles initial oil particle coalescence, while the inertial collector in the second section handles finer particle separation. This local differentiation of separation quality allows the system to maintain efficiency without requiring a final flow filter that would become blocked.
4Reliability
If two valves are added to the crankcase ventilation system to prevent overpressurization and maintain pressure balance, then system reliability is improved, but manufacturing effort and device complexity significantly increase
Solution Approach 1:
The separator body is segmented into multiple functional sections that work together to maintain pressure balance. The first section with the coalescer filter and the second section with the inertial collector are designed to handle separation tasks in sequence, naturally managing pressure without requiring additional valves.
Solution Approach 2:
The separator body serves multiple functions: it acts as both a coalescer filter housing and an inertial collector housing, and also functions as a pressure management system. This multi-functionality eliminates the need for separate pressure control valves, reducing manufacturing effort while maintaining system 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
This design achieves high separation efficiency for fine oil particles, reduces maintenance needs, and prevents excessive pressure in the crankcase, ensuring reliable engine operation with a simple and cost-effective structure.
Implementation Method 1
at least one diffusion separator body (2, 2') made of a gas- and oil-permeable material, in particular a fiber body, foam body or sintered body, which serves to separate the oil mist carried in the crankcase ventilation gas by diffusion separation from the gas
Implementation Method 2
at least one impact separation surface (4, 4'), in particular a baffle plate, arranged behind the gas channels (20) at a distance from the diffusion separator body (2, 2'), viewed in the flow direction of the crankcase ventilation gas, wherein the crankcase ventilation gas flowing through the free gas channels (20) can impinge on the impact separation surface (4, 4') and can be separated from the gas by impact separation
Data Source
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AI summary
The invention relates to an oil mist separator (1) of an internal combustion engine, comprising at least one gas-permeable diffusion separation body (2), through which a crankcase ventilation gas of the internal combustion engine can flow and in which oil mist present in the crankcase ventilation gas can be separated from the gas. The novel oil mist separator is characterized in that in the or each diffusion separation body (2) additionally continuous free gas channels (20) are formed, and that, viewed in the flow direction of the crankcase ventilation gas, behind the gas channels (20) at least one further diffusion separation body (2'), or an impingement separation surface (4) is disposed at a distance from the or each diffusion separation body (2).