Gas/liquid separator
This invention concerns air and oil separators and, more particularly, a separator for use on aircraft which will keep a hydraulic system substantially totally free of entrained air. 
     A large number of hydraulic power losses occur in aircraft hydraulic systems because of air entrained in the systems. These losses primarily occur during negative &#34;g&#34; flight, during engine start up at cold temperatures, and immediately following the operation of a large differential area actuator. Most of this type of power loss can be attributed to the lack of an adequate pump suction pressure, and can occur during engine start up after a cold soak and also following the operation of the large differential area actuator when accompanied by a hydraulic or other flight control activity. When a system contains large bubbles of free, i.e. entrained, air all three conditions increase the possibilities for pump air lock. 
     Although the most direct method of preventing the occurrence of entrained air is to preclude its entry after the system has been properly bled, air can nevertheless enter a system after bleeding under several conditions some of which are replacement of components, engine shut down under cold ambient conditions, operating one flight control system while the other is not pressurized, and servicing a system with fluid having a high air content. With proper equipment and using proper precautions, air entering the system during the last two events can be held to a very minimal amount. However, in the first two events listed the system must be bled after the occurrence of either event to be sure that any which may have entered the system has been removed. In any event, extraordinary efforts are required to keep hydraulic systems totally free of entrained air. 
     Prior art systems for removing such entrained air have been found to perform adequately under most circumstances, however, no device is known which is adaptable to aircraft hydraulic systems which require a large capacity pump having stringent flow rates and operating pressure parameters. The present invention provides a system which not only effectively removes entrained air but also prohibits pump air lock. 
     Accordingly, an object of the present invention is to provide an air separator for use on aircraft which will maintain aircraft hydraulic systems substantially totally free of entrained air. 
     Another object of this invention is to provide an air separator for use in aircraft hydraulic and other systems which contain relatively large bubbles among smaller sizes and is effective during negative &#34;g&#34; flight, engine start up at cold temperatures, and immediately following the operation of a large differential area actuator. 
     A further object of this invention is to provide an air separator which removes substantially all air entrained in oil systems and also prohibits pump air lock. 
    
    
     Other objects, advantages and novel features of the invention will become apparent when considered in conjunction with the accompanying drawings in which like numerals represent like parts throughout and wherein: 
     FIG. 1 is a sectional perspective view of one embodiment of the invention; 
     FIG. 2 is an enlarged front elevation of the operative components of the embodiment of FIG. 1; 
     FIG. 3 is a plan view of the baffle assembly of FIG. 2 taken along a line substantially corresponding to line 3--3 therein; and 
     FIG. 4 is a front elevation of the air separator of FIG. 1 illustrating the position of the inlet and outlet passages therein. 
    
    
     The present invention, in general, separates entrained air from the oil in a hydraulic system by forcing the bubbles toward the center of a holding chamber through centrifugal force, discharging air-free oil from the periphery of the chamber, directing oil with air entrained therein centrally into an upper chamber where further separation occurs, and combining air-free oil from the upper chamber and from the initial chamber into a common discharge outlet. The air collected in the upper chamber is bled therefrom either continuously or at selected intervals. 
     Referring to the drawings, the perspective view of FIG. 1 shows an air separator 11 having in the lower portion an oil receiving preferably cylindrical chamber 12 into which hydraulic system oil is introduced through an inlet 13 along the periphery of chamber 12 so as to provide a tangential flow of fluid around the chamber as indicated by arrow 14. Chamber 12 extends longitudinally to a circumferential plate 15 which is provided with a central opening 16 to permit selected egress of oil with entrained air bubbles. Air separator 11 has an enlarged central portion 19 within which is formed an annular chamber 20 surrounding the upper portion of receiving chamber 12 and in which are positioned a plurality of baffles, not shown in this view, disposed to change circular motion of the fluid to radial motion. Access to chamber 20 is provided via a circumferential slot 23 which is formed between the upper end of the chamber 12 cylinder and the bottom of a circumferential ring 25 which is secured by welding or other means to plate 15. Above plate 15, a conical chamber 26 terminates in a circumferential wall 27 formed in the separator. 
     Mounted above chamber 26 is a centrally positioned funnel 32 which is secured preferably by welding to a circumferential plate 33 in an upper separator cylinder 34. Cylinder 34 is divided into two chambers by a plate 37, with plate 37 spaced slightly from the walls of cylinder 34 to provide communication between a lower chamber 40 and an upper chamber 41 thereof. An air and oil inlet tube 43 is affixed in sealed relationship to funnel 32 preferably by welding and terminates in an off-center position in plate 37. Tube 43 and plate 37 are also affixed in the same manner to provide support for plate 37. Plate 37 may also be attached at selected points around its circumference to cylinder 34 for additional support. Chamber 40 collects oil flowing from chamber 41 and allows for further settling out of entrained air before the fluid therein reaches the top of an outlet tube 45 selectively centrally spaced from plate 37. Fluid flows through either branch 46 or 47 of tube 45 and exits through orifices 48 and 49 positioned in respective separator outlets 50 and 51. Chamber 41 terminates in a bleed valve assembly 55 positioned at the uppermost end thereof. 
     FIG. 2 is an enlarged view of substantially the entire air separator and shows the position of baffles 58 in chamber 20 as well as a clearer view of the positions and shapes of the inlet and outlet tubes 43 and 45, respectively. FIG. 3 is a sectional view of the baffle assembly which includes a baffle-supporting annular plate 60 which is spaced from the outer wall of chamber 12 as indicated at 61 to permit egress of fluid via slot 23 to outlets 50 and 51 as indicated by arrows 53. FIG. 4 is a front elevation of separator 11 and illustrates one form of configuration of a restriction in inlet 13 such as a rectangular opening 64 to act as a choke and force the fluid into a circular motion about chamber 12. 
     The perspective view of FIG. 1 illustrates the components as well as the operation of the device. The oil having entrained air is forced into inlet 13 through slot 64 which produces a swirling motion in chamber 12 and indicated by arrows 14 and 65. The swirling motion creates a centrifugal force action on the oil and air mixture which force causes the heavier, air-free, oil to move to the outer walls of the chamber and leaves the lighter oil having entrained air in the central portion of the chamber. Air-free oil is forced out of chamber 12 through slot 23 as indicated by arrows 53. Oil still having air entrained flows through opening 16 into chamber 26 from which chamber it is diverted by funnel 32 into tube 43 and thereafter into upper chamber 41 of cylinder 34. The entrained air collects in the upper area of chamber 41 and is vented through vent 55. The oil in chamber 41 is forced to the perimeter thereof by plate 37 and will have all or substantially all of its entrained air removed by the time it flows downward past the edge of the plate 37 into chamber 40. Tube 45 conducts the oil from chamber 40 to tubes 46 and 47 and thence to outlets 50 and 51. 
     There is thus provided an air separator which combines the use of centrifugal force to cause bubbles to collect toward the center of the initial chamber of the device and a vented air chamber in the upper portion of the device from which substantially completely air-free oil flows downward to the outlet while bubbles rise and are vented. The initial chamber is in effect a centrifuge the entrance to which is choked to increase fluid velocity. The choked entrance at the periphery of the chamber forces the air-contaminated oil into a circular motion or vortex which motion is carried to an upper portion of the chamber where initial separation of air-free oil and air-contaminated oil occurs. A lid, plate 15, at the top of this chamber allows oil in the center thereof to be forced upward through a central opening into a second chamber from where it enters an inverted funnel and then proceeds upward through an internal tube into an air settling chamber. The height of plate 15 above the inlet to the separator is selected so as to sustain a classical centrifugal vortex at the minimum fluid velocity through opening 64. Heavier oil, i.e. oil with no air entrained therein, is permitted to escape from the receiving chamber via a circumferential slot while the less dense oil containing bubbles passes up through the funnel and outlet tube. 
     Upon entering the air-holding or air-settling chamber above plate 37, the velocity of the oil, is reduced and the bubbles are free to &#34;settle&#34; from the oil and remain in chamber 41 as the oil exits chamber 41 into chamber 40 around the periphery of plate 37 and enters tube 45, and thence tubes 46 and 47. To assist the bubbles in moving into chamber 41 a circulation into and out thereof is caused by the aspiration effect created by the placement of tubes 46 and 47 in orifices 48 and 49, respectively. The more dense oil from chamber 12 flows into outlets 50 and 51 via slots 23 and 61 and orifices 48 and 49 causing the fluid pressure in outlets 50 and 51 to be lower than that of chamber 12. With the tubes 46 and 47 centrally disposed within orifices 48 and 49, respectively, the fluid pressure in chamber 40 and 41 is thus also lower than that of chamber 12 causing the circulation into and out of chamber 41. 
     The restriction to fluid flow caused by orifices 48 and 49 increases the velocity and thus the momentum of the fluid as it flows through these orifices. This increased momentum past the ends of tubes 46 and 47 being centrally disposed within orifices 48 and 49, respectively, further enhances the circulation into and out of chamber 41. Orifices 48 and 49 can be replaced by venturi tubes where space permits and where the fluid pressure drop through the separator must be minimized. The same circulation into and out of chamber 41 can be achieved using venturi constrictions rather than orifices with a smaller pressure drop between chamber 12 and outlets 50 and 51. The upper end of tube 45 is centrally positioned in cylinder 34, both axially and radially, so that when the separator assumes any attitude or is under any condition of acceleration the inlet of tube 45 will remain covered with fluid and not air. Plate 37 is placed immediately above the end of tube 45 to provide for maximum settling out of any remaining entrained air before the oil in chamber 40 enters tube 45. That is, plate 37 forces the residual fluid and the bubbles entrained therein to the periphery of chamber 41 before this volume of fluid enters chamber 40 and ultimately tube 45, allowing more time for the entrained air bubbles to settle out of the fluid. Chambers 40 and 41 remain full of fluid until the separated air displaces an equal amount of fluid in chamber 41. The flow rates through tubes 43 and 45 are selected such that the flow into chamber 41 is greater than the maximum expected rate of entrained air flow into the separator. Tubes 45 and 46 may be located other than as shown so long as the end of tube 45 is spaced from plate 37 in the manner shown and the ends of tubes 46 and 47 terminate in outlets 48 and 49 as shown. 
     Where the separator is installed in aircraft hydraulic systems, such systems must be bled wherever air may be trapped therein and would have a deleterious effect on the system. If there is no place in the system where air can be trapped, the system may be bled at vent 55 provided that all of the actuators are cycled sufficiently so that all of the fluid in the system passes through the separator at least once. That is, the separator should be so placed in such systems that all of the fluid must be passed through it before going to the pump. 
     It will be appreciated that the invention is not limited to air/oil separation but may be applied in the separation of many other gases from liquids. Also, the separator may be configured to have only one outlet so that only one outlet tube such as 46 or 47 would be required. Although various components are either welded together or threaded together as indicated in FIG. 2, it will be appreciated that these components may be joined in other fashion within the concept of the invention. 
     Obviously, many modifications and variations of the present invention are possible in the light of the foregoing teachings.