3D-Printed Oil Separation for Reciprocating Compressors

Abstract

A 3D-printed oil separation assembly for use in a reciprocating compressor is provided. The compressor includes a suction chamber, a crankcase chamber, and at least one partition member at least partially separating the suction chamber and the crankcase chamber. The at least one partition member further includes at least one opening. The 3D-printed oil separation assembly comprises a coalescing structure positioned within the crankcase chamber adjacent the at least one partition member at the at least one opening; and at least one securing structure secured in operable relation with the at least one demisting structure so as to secure the coalescing structure relative to the opening. The coalescing structure comprises at least one structure selected from the group consisting of a baffled structure, a demisting structure, and combinations thereof. At least a portion of the coalescing structure is 3D-printed.

1 . A 3D-printed oil separation assembly for use in a reciprocating compressor, the compressor comprising a suction chamber, a crankcase chamber, and at least one partition member at least partially separating the suction chamber and the crankcase chamber, the at least one partition member including at least one opening, the oil separation assembly comprising:
 a coalescing structure, wherein at least a portion of the coalescing structure is positioned within the crankcase chamber with respect to the at least one partition member at the at least one opening; and   at least one securing structure secured in operable relation with the coalescing structure so as to secure the at least one coalescing structure relative to the opening,   wherein at least a portion of the coalescing structure is 3D printed.   
     
     
         2 . The 3D-printed oil separation assembly of  claim 1 , wherein the coalescing structure comprises at least one structure selected from the group consisting of a baffled structure, a demisting structure, and combinations thereof. 
     
     
         3 . The 3D-printed oil separation assembly of  claim 2 , wherein the coalescing structure comprises at least one baffled structure. 
     
     
         4 . The 3D-printed oil separation assembly of  claim 3 , wherein the at least one baffled structure comprises an outer wall and a plurality of sloped baffles. 
     
     
         5 . The 3D-printed oil separation assembly of  claim 4 , wherein the plurality of sloped baffles comprises at least a first sloped baffle having a free end and a secured end and a subsequent sloped baffle having a free end and a secured end, wherein the secured ends are secured to the outer wall such that the free ends are oppositely disposed and the free end of the first baffle is closer to the secured end of the subsequent baffle than the secured end of the first baffle to the free end of the subsequent baffle. 
     
     
         6 . The 3D-printed oil separation assembly of  claim 5 , wherein the first and subsequent sloped baffles are each secured to the outer wall at an angle from 5° to 30°. 
     
     
         7 . The 3D-printed oil separation assembly of  claim 5 , wherein the distance between the free end of the first baffle and the secured end of the subsequent baffle is greater than or equal to a cross-sectional area of the opening. 
     
     
         8 . The 3D-printed oil separation assembly of  claim 3 , wherein the at least one baffled structure is wholly 3D printed. 
     
     
         9 . The 3D-printed oil separation assembly of  claim 3 , wherein the coalescing structure further includes at least one demisting structure. 
     
     
         10 . The 3D-printed oil separation assembly of  claim 2 , wherein the coalescing structure comprises at least one demisting structure. 
     
     
         11 . The 3D-printed oil separation assembly of  claim 10 , wherein the at least one demisting structure is wholly 3D-printed. 
     
     
         12 . The 3D-printed oil separation assembly of  claim 1 , wherein the at least one securing structure comprises a first support, a second support, and a locking structure. 
     
     
         13 . The 3D-printed oil separation assembly of  claim 1 , wherein the coalescing structure is wholly 3D-printed. 
     
     
         14 . A reciprocating compressor comprising:
 a suction chamber;   a crankcase chamber;   a partition member at least partially separating the suction chamber and the crankcase chamber and comprising at least one opening; and   at least one 3D-printed oil separation assembly comprising
 a coalescing structure, wherein at least a portion of the coalescing structure is positioned within the crankcase chamber with respect to the at least one partition member at the at least one opening; and 
 at least one securing structure secured in operable relation with the coalescing structure so as to secure the at least one coalescing structure relative to the opening, 
 wherein at least a portion of the coalescing structure is 3D printed. 
   
     
     
         15 . The reciprocating compressor of  claim 14 , wherein the coalescing structure comprises at least one structure selected from the group consisting of a baffled structure, a demisting structure, and combinations thereof. 
     
     
         16 . The reciprocating compressor of  claim 15 , wherein the coalescing structure comprises at least one baffled structure. 
     
     
         17 . The reciprocating compressor of  claim 16 , wherein the at least one baffled structure comprises an outer wall and a plurality of sloped baffles. 
     
     
         18 . The reciprocating compressor of  claim 17 , wherein the plurality of sloped baffles comprises at least a first sloped baffle having a free end and a secured end and a subsequent sloped baffle having a free end and a secured end, wherein the secured ends are secured to the outer wall such that the free ends are oppositely disposed and the free end of the first baffle is closer to the secured end of the subsequent baffle than the secured end of the first baffle to the free end of the subsequent baffle. 
     
     
         19 . The reciprocating compressor of  claim 14 , wherein the coalescing structure is entirely 3D-printed. 
     
     
         20 . A method of retrofitting a reciprocating compressor with an oil separation assembly, the compressor comprising a suction chamber, a crankcase chamber, and at least one partition member at least partially separating the suction chamber and the crankcase chamber, the at least one partition member including at least one opening, the method comprising:
 identifying the internal dimensions of the compressor at the at least one opening;   designing a coalescing structure configuration;   programming a 3D printer based on the internal dimensions identified and coalescing structure configuration;   3D printing at least a portion of the coalescing structure; and   securing the coalescing structure at the opening on the crankcase chamber-side of the partition member.   
     
     
         21 . The method of  claim 20 , wherein the step of 3D printing at least a portion of the coalescing structure comprises 3D printing the entirety of the coalescing structure. 
     
     
         22 . A 3D-printed oil separation assembly for use in a reciprocating compressor, the compressor comprising a suction chamber, a crankcase chamber, and at least one partition member at least partially separating the suction chamber and the crankcase chamber, the at least one partition member including at least one opening, the oil separation assembly comprising:
 a coalescing structure, wherein at least a portion of the coalescing structure is positioned within the crankcase chamber with respect to the at least one partition member at the at least one opening; and   at least one securing structure secured in operable relation with the coalescing structure so as to secure the at least one coalescing structure relative to the opening,   wherein at least a substantial portion of the coalescing structure is 3D-printed.   
     
     
         23 . The 3D-printed oil separation assembly of  claim 22 , wherein the coalescing structure is wholly 3D-printed. 
     
     
         24 . The 3D-printed oil separation assembly of  claim 23 , wherein the coalescing structure is a baffled structure. 
     
     
         25 . The 3D-printed oil separation assembly of  claim 23 , wherein the coalescing structure comprises a baffled structure and the baffled structure is wholly 3D-printed. 
     
     
         26 . The 3D-printed oil separation assembly of  claim 25 , wherein the coalescing structure further comprises a demisting structure. 
     
     
         27 . The 3D-printed oil separation assembly of  claim 26 , wherein the demisting structure is not 3D-printed.