Rotating Coalescer Element Axial Flow Clogging
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Solution Overview
Problem
Existing crankcase ventilation systems face issues with filter media clogging due to insoluble particles, leading to declining permeability and increased pressure loss, requiring frequent replacement of rotating coalescer elements.
Innovation Solution
A rotating coalescer element with a coiled filter media pack having spacers to maintain a gap, forming an axial flow channel, which enhances separation efficiency and reduces clogging by allowing for easier drainage of coalesced liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media is used to separate aerosols and oils from blowby gases, then separation efficiency is improved, but filter media becomes clogged by insoluble particles leading to declining permeability and increased pressure loss
Solution Approach 1:
The filter media is segmented into multiple layers with different pore sizes and properties. The first layer has larger pores to capture insoluble particles, while subsequent layers have progressively smaller pores to capture aerosols and oils. This segmentation prevents clogging of the entire media by distributing the filtration function across multiple specialized layers.
Solution Approach 2:
Different regions of the filter media have different properties tailored to specific functions. The outer layers have higher porosity to handle particle loading, while inner layers have lower porosity for fine aerosol filtration. This local differentiation allows each region to optimize its performance without compromising the entire filter's longevity.
2Productivity
If rotating coalescer element is used to reduce pressure drop and improve filtering, then crankcase ventilation performance is improved, but the element requires periodic replacement due to pore clogging
Solution Approach 1:
The filter media is designed to be replaceable in sections or layers. When the outer layers become clogged with insoluble particles, they can be discarded and replaced, while the inner layers that have not yet clogged are retained and reused. This extends the overall service life of the coalescer element.
Solution Approach 2:
The coalescer element is designed to rotate during operation, which dynamically redistributes the blowby gases across different portions of the filter media. This rotation prevents any single area from becoming completely saturated with contaminants, extending the effective service life of the media.
3Loss of substance
If stacks of separating plates or cones are used instead of filter media, then clogging is reduced, but separating efficiency decreases and packing density is low
Solution Approach 1:
The invention combines the advantages of both filter media and separating plates/cones by creating a composite structure. The filter media layers are positioned within a framework of separating plates or cones, allowing the system to benefit from both the high surface area of filter media and the large passage sizes of plates/cones that resist clogging.
Solution Approach 2:
The filter media is arranged in a three-dimensional configuration with varying orientations and angles, creating multiple flow paths through the media. This dimensional arrangement increases the effective surface area for separation while maintaining adequate flow passages, achieving both high efficiency and clogging resistance.
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 improves the separation efficiency and extends the service life of the rotating coalescer element by reducing clogging and maintaining permeability, thus optimizing the performance of crankcase ventilation systems.
Implementation Method 1
Some rotating coalescer elements utilize rotating coalescer elements that increase the filter efficiency of the crankcase ventilation systems by rotating the coalescer element during filtering. In rotating coalescer elements, the contaminants (e.g., oil droplets suspended and transported by blowby gases) are separated at least in part by centrifugal separation techniques.
Implementation Method 2
Additionally, the rotation of the coalescer element can create a pumping effect, which reduces the pressure drop through the crankcase ventilation system.
Data Source
AI summary
Rotating coalescer elements that maximize the radial-projected separation surface area in a given (rotating) cylindrical volume, where flow to be cleaned is passing axially upward or downward through a separating media of the rotating coalescer element. Various example package assemblies are provided with various types of rotating configurations including cylindrical coiled media packs, frustum coiled media packs, concentric cylinders, coiled metal or polymer films with and without perforations, and/or alternating layers of different materials. The described rotating coalescers may be driven by hydraulic turbine, electric motor, belt, gear or by mounting on rotating machine components, such as rotating engine shafts or connected components.