Particulate Separator With Deflector Flow Paths

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Solution Overview

Problem

In environments with high concentrations of particulates, air filters in vehicles become clogged quickly, restricting airflow and reducing engine performance, as existing technologies fail to effectively remove particulate matter before it reaches the air filter.

Innovation Solution

A particulate separator assembly with a housing, air guide, and outlet body, featuring deflectors that create multiple flow paths and a drain valve with weighted flaps, directs particulates away from the main airflow, ensuring they are collected and not passed through to the air filter, while maintaining low air resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If air filter is used to remove contaminants, then air quality is improved, but air filter becomes clogged quickly in high particulate environments

Engineering Contradiction:
Improvecontaminant removalVSAvoidair filter service life
Core Design Contradiction:
Object-affected harmful factorsVSDuration of action of stationary object

Solution Approach 1:

The particulate separator performs preliminary removal of heavy particulates before air reaches the air filter. The separator uses deflectors and gravity to cause particulates to drop into a drain chamber before the air enters the air filter, preventing the filter from becoming clogged with heavy contaminants while the filter still handles finer particles.

Inventive Principle:
Principle #10Preliminary action

2Object-affected harmful factors

If air filter removes more contaminants, then air quality improves, but airflow restriction increases

Engineering Contradiction:
Improvecontaminant removalVSAvoidairflow restriction
Core Design Contradiction:
Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The air cleaning system is segmented into two stages: a first stage particulate separator that removes heavy particulates using deflectors and gravity, and a second stage air filter that handles finer contaminants. This segmentation allows each component to be optimized for its specific function, with the separator handling the bulk of particulate removal to reduce the burden on the filter and minimize airflow restriction.

Inventive Principle:
Principle #1Segmentation

3Object-generated harmful factors

If drain valve flaps are spaced apart to allow particulate drainage, then particulate removal is improved, but air leakage increases

Engineering Contradiction:
Improveparticulate drainageVSAvoidair leakage
Core Design Contradiction:
Object-generated harmful factorsVSLoss of energy

Solution Approach 1:

The drain valve flaps are designed to be dynamic rather than fixed. During normal operation, the flaps remain closed to prevent air leakage. When particulates accumulate in the drain chamber, the weight of the particulates causes the flaps to automatically open, allowing drainage. This dynamic behavior allows the system to adapt to different operating conditions, preventing air leakage during normal operation while enabling effective drainage when needed.

Inventive Principle:
Principle #15Dynamics

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 particulate separator effectively extends the life of air filters by removing contaminants before they clog the filter, reducing airflow restrictions and maintaining engine performance with minimal impact on power output.

Implementation Method 1

The air guide has multiple deflectors that define multiple flow paths between adjacent ones of the multiple deflectors

Methodology Applied
Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

the second outlet is formed through a lower portion of the housing relative to gravity

Methodology Applied
Scientific EffectGravity: Gravitation

Implementation Method 3

the body includes two weights with one weight carried by each flap between the first end and second end, and the weights are embedded within the material of the body

Methodology Applied
Scientific EffectWeight: Gravitation

Data Source

PatentUS11458428B2Particulate separator for engine air cleaner
Publication Date: 2022.10.04 FCA US LLC
  • US11458428B2 patent drawing
  • US11458428B2 patent drawing
  • US11458428B2 patent drawing

AI summary

A particulate separator includes a housing, and air guide, and an outlet body. The housing has an inlet through which air enters an interior, a first outlet and a second outlet. The air guide is carried by the housing between the inlet and the first outlet, and has deflectors and flow paths between adjacent deflectors, the flow paths communicating with the housing interior. The outlet body has a central portion and a wall extending outwardly from the central portion. The central portion is received at least partially within the interior of the housing with a space defined between an outer surface of the central portion and an inner surface of the housing, and the central portion has an opening through which air flows through the outlet body, and the wall encloses the space so that air that flows around the central portion is blocked by the wall.