Effluent Processing Apparatus and Method for a Vehicle Air Brake Charging System

Abstract

An effluent processing apparatus comprises a coalescing element arranged to separate oil and water from an effluent mixture containing air, oil, and water from a purge valve of an air dryer. The coalescing element includes a plurality of members which define a predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom.

What is claimed is: 
     
         1 . An effluent processing apparatus comprising:
 a coalescing element arranged to separate oil and water from an effluent mixture containing air, oil, and water from a purge valve of an air dryer, wherein the coalescing element includes a plurality of members which define a predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom.   
     
     
         2 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise a predefined pattern of bristles which are arranged to provide the predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom. 
     
     
         3 . An effluent processing apparatus according to  claim 2 , wherein each bristle comprises a vertically-extending, rod-shaped member around which the effluent mixture flows to separate oil and water therefrom. 
     
     
         4 . An effluent processing apparatus according to  claim 2 , wherein the bristles comprise a polyester material having fibers. 
     
     
         5 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members are arranged in a pattern to form a shape of an internal-toothed lockwasher. 
     
     
         6 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise a predefined pattern of pleats which are arranged to provide the predefined pattern of paths through which the effluent mixture flows to separate oil and water therefrom. 
     
     
         7 . An effluent processing apparatus according to  claim 6 , wherein (i) each pleat forms a portion of a ruffled collar, and (ii) each pleat has a major surface along which the effluent mixture flows in parallel to separate oil and water therefrom. 
     
     
         8 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise (i) a first predefined pattern of pleats which are arranged to provide a first portion of the predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom, and (ii) a second predefined pattern of pleats which are arranged to provide a second portion of the predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom. 
     
     
         9 . An effluent processing apparatus according to  claim 8 , wherein (i) each pleat of the first predefined pattern of pleats forms a portion of a first ruffled collar, (ii) each pleat of the first predefined pattern of pleats has a major surface along which the effluent mixture flows in parallel to separate oil and water therefrom, (iii) each pleat of the second predefined pattern of pleats forms a portion of a second ruffled collar, (iv) each pleat of the second predefined pattern of pleats has a major surface along which the effluent mixture flows in parallel to separate oil and water therefrom, and (v) the first and second ruffled collars are nested and concentric. 
     
     
         10 . An effluent processing apparatus according to  claim 9 , wherein (i) the plurality of members comprise a third predefined pattern of pleats which are arranged to provide a third portion of the predefined pattern of paths along which the effluent mixture flows to separate oil and water therefrom, and (ii) each pleat of the third predefined pattern of pleats forms a portion of a third ruffled collar, (iii) each pleat of the third predefined pattern of pleats has a major surface along which the effluent mixture flows in parallel to separate oil and water therefrom, and (iv) the first, second, and third ruffled collars are nested and concentric. 
     
     
         11 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise a plurality of strips of substantially Z-shaped members which separate oil and water from the effluent mixture as the effluent mixture flows around the plurality of strips of substantially Z-shaped members. 
     
     
         12 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise a plurality of strips of substantially airfoil-shaped members which separate oil and water from the effluent mixture as the effluent mixture flows around the plurality of strips of substantially airfoil-shaped members. 
     
     
         13 . An effluent processing apparatus according to  claim 1 , wherein the plurality of members comprise a plurality of rows of substantially V-shaped members which separate oil and water from the effluent mixture as the effluent mixture flows around the plurality of rows of substantially V-shaped members. 
     
     
         14 . An effluent processing apparatus for a vehicle air brake charging system having an air dryer purge valve through which an effluent containing a mixture of air, oil, and water flows in a flow direction, the effluent processing apparatus comprising:
 a coalescing element arranged to separate oil and water from the effluent mixture to provide an air stream substantially devoid of oil, wherein the coalescing element is oriented parallel with the flow direction of the effluent mixture such that the effluent mixture flows substantially around or substantially along the coalescing element.   
     
     
         15 . An effluent processing apparatus according to  claim 14 , wherein the coalescing element comprises a select one of (i) a plurality of bristles, (ii) one or more ruffled collars, (iii) a plurality of strips of substantially Z-shaped members, (iv) a plurality of strips of substantially airfoil-shaped members, and (v) a plurality of rows of substantially V-shaped members. 
     
     
         16 . An effluent processing apparatus according to  claim 14 , further comprising:
 a sump disposed below the coalescing element and containing oil-holding media for holding separated oil until the separated oil can be removed from the sump.   
     
     
         17 . An effluent processing apparatus according to  claim 16 , wherein the sump containing the oil-holding media is removable and replaceable. 
     
     
         18 . A method of operating an effluent processing apparatus to separate oil and water from a flow of effluent mixture containing air, oil, and water, the method comprising:
 receiving the flow of effluent mixture in a first direction into a center portion of a chamber;   redirecting the flow of effluent mixture from the center portion of the chamber in a second direction which is transverse to the first direction and towards an outer perimeter portion of the chamber;   passing the flow of effluent mixture along a predefined pattern of paths to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber;   temporarily retaining the separated oil to provide a clean stream of air and water devoid of oil that flows into the outer peripheral chamber; and   exhausting the clean stream from the outer perimeter portion of the chamber to atmosphere.   
     
     
         19 . A method according to  claim 18 , wherein passing the flow of effluent mixture along a predefined pattern of paths to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber includes:
 passing the flow of effluent mixture along a predefined pattern of paths formed by bristle-members to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber.   
     
     
         20 . A method according to  claim 18 , wherein passing the flow of effluent mixture along a predefined pattern of paths to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber includes:
 passing the flow of effluent mixture along a predefined pattern of paths formed by major surfaces of a pleated collar to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber.   
     
     
         21 . A method according to  claim 18 , wherein passing the flow of effluent mixture along a predefined pattern of paths to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber includes:
 passing the flow of effluent mixture along a predefined pattern of paths formed by a select one of (i) strips of substantially Z-shaped members, (ii) strips of substantially airfoil-shaped members, and (iii) rows of substantially V-shaped members to separate oil and water from the effluent mixture as the effluent mixture flows from the center portion of the chamber to the outer perimeter portion of the chamber.   
     
     
         22 . A method according to  claim 18 , further comprising:
 exhausting the separated water to atmosphere to return the water to atmosphere.