Pre-separator Impact Segments for Spray Mist Extraction
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Solution Overview
Problem
The frequent contamination and rapid replacement of filter fleeces in spray mist extraction systems and painting systems result in high material, maintenance, and disposal costs due to the inability to effectively pre-separate paint and lacquer particles from the air.
Innovation Solution
A pre-separator with two rows of offset impact segments that utilize forced suction to deposit the majority of paint and varnish particles, reducing the need for filter fleece replacement and facilitating easy cleaning with a low-adhesion plastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter fleece is used to capture paint particles in spray mist extraction systems, then paint particles are filtered out, but the filter fleece becomes contaminated quickly requiring frequent replacement
Solution Approach 1:
The pre-separator divides the air flow path into multiple segments using two rows of offset impact segments. Paint particles are captured in stages as they navigate through the labyrinthine structure, with each segment contributing to particle deposition before air reaches the filter fleece.
Solution Approach 2:
The pre-separator performs preliminary separation of paint particles from air flow before the contaminated air reaches the filter fleece. By capturing the majority of particles in advance through impact and adhesion on the pre-separator segments, the filter fleece is protected from rapid contamination.
2Loss of substance
If a pre-separator with impact segments is added to reduce filter replacement frequency, then material costs are reduced, but device complexity increases
Solution Approach 1:
The pre-separator segments are constructed from thin-walled plastic material that provides the necessary structural integrity while maintaining low weight and ease of manufacturing. The thin-walled design allows for complex geometries without significantly increasing material cost or manufacturing complexity.
Solution Approach 2:
The pre-separator utilizes plastic material with specific adhesion properties that allow paint particles to attach during operation but be easily removed during cleaning. This material selection balances structural requirements with functional performance, avoiding the need for complex multi-material constructions.
3Productivity
If the pre-separator captures most paint particles, then filter fleece replacement is reduced by up to 80%, but the pre-separator requires cleaning maintenance
Solution Approach 1:
The plastic material used in the pre-separator has specific surface properties that change its interaction with paint particles: during operation, particles adhere to the segments; during cleaning, the adhesion is easily overcome allowing rapid removal of accumulated paint without requiring complex disassembly or specialized cleaning procedures.
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 solution reduces filter fleece replacement frequency by up to 80% and simplifies maintenance by allowing easy detachment of paint particles, thereby minimizing material and disposal costs.
Implementation Method 1
the majority of the paint and varnish particles in the air are deposited on the impact segments due to the forced suction and suction through the labyrinth-like pre-separator
Implementation Method 2
the material used ensures very little adhesion of the paint and varnish particles and they can be detached or peeled off very easily
Data Source
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AI summary
The pre-separator (1) has a base frame (4) provided with an opening (5). Swirl segments are spaced from each other and are oriented horizontally or vertically. The pre-separator is made of plastic, which possesses characteristics such that dye and color are removably and/or detachably adhered. The base frame is provided with a stop edge. The swirl segments are provided in the opening. A bonded-fiber filter (13) is provided in the opening. The swirl segments extend towards a frame part (11) that is arranged opposite to another frame part (10).