Staggered Post Pre-Separator for Engine Oil Separation
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Solution Overview
Problem
Internal combustion engines face inefficiencies in air/liquid separation due to high load on main separators, leading to oil carryover and re-entrainment, and pressure differentials causing backflow, which reduces the effectiveness of crankcase ventilation systems.
Innovation Solution
A pre-separator system with a staggered array of posts and hooks is used to separate liquid particles from air/liquid mixtures, reducing flow velocity and likelihood of re-entrainment, and is integrated with a main separator to improve oil drainage and recirculation, thereby reducing the load on the main separation device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a main separator is used to separate liquid particles from air/liquid mixture, then separation effectiveness is improved, but the device complexity and load on the separator increase leading to oil carryover and re-entrainment
Solution Approach 1:
The separator is divided into two distinct stages: a pre-separator with multiple posts arranged in staggered arrays that provide initial separation, and a main separator that handles the pre-separated flow. This segmentation distributes the separation load, preventing overload of the main separator and reducing oil carryover while maintaining effective separation.
Solution Approach 2:
The pre-separator performs preliminary separation of liquid particles from the air/liquid mixture before the flow enters the main separator. By removing a significant portion of liquid particles in advance, the main separator receives a lighter load, improving its effectiveness and reducing the likelihood of re-entrainment.
2Reliability
If flow velocity is reduced in the separator, then re-entrainment is reduced, but the separator volume increases
Solution Approach 1:
Instead of reducing velocity through a larger volume, the staggered array of posts creates multiple separation zones throughout the flow path. The posts are arranged in alternating patterns that extend the separation process along the flow direction, achieving velocity reduction and re-entrainment prevention without proportionally increasing the separator volume.
Solution Approach 2:
The separator features localized separation zones created by individual posts with collection pockets at strategic positions. Each post creates a local low-velocity zone where liquid particles can be captured, and the staggered arrangement ensures these local zones are distributed throughout the separator, achieving effective separation without requiring uniform volume expansion.
3Reliability
If multiple posts with hooks are added to the pre-separator, then liquid particle collection is improved, but manufacturing complexity increases
Solution Approach 1:
The posts are designed with a porous or permeable structure that allows liquid particles to be captured on the surface and within the porous matrix. The collection pockets are integrated into the post structure, and the porous nature of the posts enhances liquid particle collection efficiency while maintaining a relatively simple overall geometry that is amenable to manufacturing.
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 pre-separator effectively manages flow velocity, reduces re-entrainment, and extends service intervals by improving filtering and drainage, while being lightweight and cost-effective, and can be used as a standalone unit or in conjunction with other systems.
Implementation Method 1
a convex end portion having an impaction surface contacting the air/liquid mixture, a portion of liquid particles from the air/liquid mixture adhering as a liquid film to the impaction surface
Implementation Method 2
a portion of liquid particles from the air/liquid mixture adhering as a liquid film to the impaction surface
Implementation Method 3
the collection pocket configured to collect the portion of liquid particles adhered as a liquid film to the impaction surface
Data Source
AI summary
A separator system comprises a main separator, and an additional separator including one of a pre-separator, post separator, or line-of-sight baffle. The additional separator separates liquid particles from an air/liquid mixture and comprises an inlet, an air outlet, a liquid outlet, and a plurality of posts disposed between the inlet and the air outlet. The posts are arranged in a staggered array and comprise a convex end portion having an impaction surface, a portion of liquid particles from the air/liquid mixture adhering as a liquid film to the impaction surface, and a hook end portion positioned downstream the convex end portion and including hooks having an end and a collection pocket disposed between the impaction surface and the end. The collection pocket collects the portion of liquid particles adhered as the liquid film to the impaction surface.