Oil Mist Separator Mechanical Fastening
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Solution Overview
Problem
Existing oil mist separators face issues with the fiber laminate coming off after long use due to inadequate fixation methods, such as bonding or welding, which complicates installation and maintenance.
Innovation Solution
An oil mist separator design featuring a housing body with upper and lower members forming a gas flow passage, including a separator unit with a perforated plate, holding studs, and an impinge plate with a fiber material piece sandwiched between the studs and the plate, providing stable attachment without bonding materials and allowing easy assembly and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fiber laminate is fixed to the impinge wall using bonding or welding, then the oil mist separation performance is improved, but the fiber laminate may come off after long use and the installation work becomes complicated
Solution Approach 1:
The separator is divided into a front unit (perforated plate with holding studs) and a rear unit (base plate with connecting studs and impinge plate). The fiber material is positioned between these units, which are then coupled together. This segmentation allows the fiber material to be securely held by mechanical interlocking rather than bonding, improving both reliability and ease of installation.
Solution Approach 2:
The patent replaces the chemical bonding or welding method with a mechanical fastening system using holding studs and connecting studs. The studs engage with corresponding openings and features in the front and rear units, providing secure mechanical retention of the fiber material without requiring adhesives or thermal processes.
2Strength
If bonding or welding is used to fix the fiber laminate, then the attachment is strong, but the work for bonding or welding to a desired position is not easy
Solution Approach 1:
By segmenting the separator into front and rear units with integrated stud features, the design eliminates the need for separate bonding or welding operations. The modular units can be manufactured independently and then assembled through simple mechanical coupling, reducing manufacturing complexity while maintaining attachment strength.
Solution Approach 2:
The holding studs and connecting studs are designed to self-align and self-secure during assembly. The studs engage with predetermined openings and features, allowing the units to be coupled together without requiring precise positioning or additional fastening operations, thereby simplifying the manufacturing process.
3Ease of operation
If the fiber material is securely held by mechanical fastening, then the assembly is easy and maintenance is reduced, but the structure becomes more complex
Solution Approach 1:
The holding studs and connecting studs serve multiple functions: they provide mechanical retention for the fiber material, structurally couple the front and rear units, and define the spatial relationship between components. This multi-functionality reduces the need for separate retention mechanisms, simplifying the overall structure despite the added fastening features.
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 solution ensures stable oil mist separation performance, easy assembly, and reduced maintenance by securely holding the fiber material in place, improving both oil mist trapping efficiency and pressure loss performance compared to previous designs.
Implementation Method 1
a fiber material piece put on a front surface of the impinge plate... the fiber material piece is sandwiched between the leading ends of the holding studs and the impinge plate
Implementation Method 2
a plurality of holding studs extending rearward from the perforated plate... a plurality of connecting studs extending rearward from the base plate... the fiber material piece is sandwiched between the leading ends of the holding studs and the impinge plate
Implementation Method 3
the blow-by gas is forced to pass through the openings. With this passing, the blow-by gas is highly accelerated before impinging against the impinge wall
Data Source
Figure 1
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AI summary
A separator unit of an oil mist separator comprises a front unit including a perforated plate and a plurality of holding studs extending rearward from the perforated plate, a rear unit placed behind the perforated plate and including a base plate that is to be intimately put on a rear surface of the perforated plate and has an opening sized to permit insertion of the holding studs of the front unit, a plurality of connecting studs extending rearward from the base plate and an impinge plate held by leading ends of the connecting studs, and a fiber material piece put on the impinge plate, wherein when the front unit is coupled with the rear unit having the holding studs inserted through the opening of the base plate, the fiber material piece is sandwiched between the leading ends of the holding studs and the impinge plate.