Patent Publication Number: US-2018028955-A1

Title: Drip leg for air handling system

Description:
FIELD 
     The present invention relates generally to pneumatic systems, and more particularly, to a sediment trap and pneumatic apparatus for air handling systems. 
     BACKGROUND 
     Air handling systems, also called pneumatic systems, are commonplace in various industries, such as the automotive industry. In a typical air handling system, atmospheric air is compressed and provided to various locations throughout a factory floor via supply piping that is often comprised of iron. The compressed air is subsequently filtered, pressure-regulated, oiled, or otherwise conditioned prior to being supplied to pneumatic tooling or other apparatuses requiring pressurized air. 
     Conventionally, filtering of the compressed air is performed using various filter elements, whereby multiple screens filter various-sized contaminants from the compressed air prior to the compressed air reaching the pneumatic tooling or apparatuses. In a typical factory environment, the quality of incoming air can be poor, and corrosion within the supply piping can be significant. Thus, depending on the condition of the air prior to compression, as well as the condition of the piping and other factors, the filter screens may become saturated or plugged in a relatively short period of time, thus leading to frequent maintenance or replacement of the filter screens. 
     SUMMARY 
     The present disclosure provides a novel system and apparatus for capturing contaminants such as debris, scale, liquids, large particles or sediment within a compressed air system prior to the compressed air being conditioned. Accordingly, the following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later. 
     The present disclosure is directed generally toward a sediment trap, also called a drip leg, for substantial removal of contaminants in a stream of compressed air prior to the compressed air being subsequently conditioned. The sediment trap of the present disclosure comprises a chamber having a top cap, a bottom cap, and a sidewall extending between the top cap and bottom cap. The top cap, bottom cap, and sidewall generally enclose an interior region of the chamber. An inlet conduit is operably coupled to the top cap of the chamber. The inlet conduit fluidly couples the interior region of the chamber to an exterior region of the chamber, such as to a source of compressed air. 
     In accordance with one exemplary aspect, an outlet conduit is further operably coupled to the top cap, wherein the outlet conduit has a first outlet axis and second outlet axis associated therewith. The outlet conduit further fluidly couples the interior region of the chamber to the exterior region of the chamber, such as to one or more supplemental air preparation apparatus. The first outlet axis is generally parallel to the inlet axis, and the second outlet axis is offset from the first inlet axis by approximately 90 degrees. One of the inlet conduit and outlet conduit is further hollow and extends into the interior region of the chamber by at least one-quarter of a length of the chamber along one of the inlet axis and first outlet axis, respectively. 
     A clean-out conduit is further provided, wherein the clean-out conduit is operably coupled to the bottom cap, and wherein the clean-out conduit selectively fluidly couples the interior region and exterior region of the chamber. 
     Accordingly, as provided in one exemplary aspect, compressed air carrying various contaminants enters the chamber of the sediment trap from the top of the sediment trap via the inlet conduit, wherein the compressed air exits the inlet conduit in a downward manner within the interior region of the chamber. Once the compressed air exits the inlet conduit, it is forced to travel 180 degrees to exhaust through the outlet conduit, thus allowing the contaminants to fall via gravity to the bottom cap of the chamber. 
     Advantageously, the present disclosure provides the first outlet axis as being parallel to the inlet axis at the top cap of the chamber, whereby the outlet conduit comprises a 90-degree change in direction of the flow of compressed air, thereby maximizing the degree of fall-out of contaminant material due to gravity, while further changing the direction of flow of the compressed air. A further advantage to the present disclosure is the ability of the second outlet axis to be generally coaxial with additional supplemental air preparation apparatuses, such as filters, regulators, valves, and the like, whereby the sediment trap of the present disclosure minimizes a footprint of the air preparation apparatuses. 
     In accordance with another example, the clean-out conduit comprises a valve configured to be selectively positioned in an open position and closed position. As such, the valve is configured to selectively fluidly couple the interior region and exterior region of the chamber, wherein in the open position, the valve is configured to evacuate sediment deposited on the bottom cap upon air pressure being applied to the inlet. 
     According to yet another exemplary aspect, an air preparation system is provided, wherein the air preparation system comprises the above-described sediment trap, in addition to one or more supplemental air preparation apparatuses. As such, the outlet conduit of the sediment trap is fluidly coupled to the one or more supplemental air preparation apparatuses in an advantageous manner. The one or more supplemental air preparation apparatuses, for example, can comprise one or more of an electrically-operated on/off valve, a manually-operated on/off valve, a soft start valve, a distribution module, a branch module, a pressure regulator, an electronic pressure regulator, a particulate filter, a coalescing filter, and a water separator. Accordingly, the second axis of the outlet conduit is coaxial with an inlet to one or more of the one or more supplemental air preparation apparatuses, thus providing a compact air preparation system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic representation of an exemplary sediment trap in accordance with one aspect of the present disclosure. 
         FIG. 2  is a schematic representation of an exemplary air preparation system incorporating a sediment trap in accordance with one aspect of the present disclosure. 
         FIG. 3  is a cross-sectional illustration of an exemplary sediment trap in accordance with another aspect of the present disclosure. 
         FIG. 4  is a cross-sectional illustration of yet another exemplary sediment trap in accordance with further aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure will be described with reference to the drawings wherein like reference numerals are used to refer to like elements throughout. It should be understood that the description of these aspects are merely illustrative and that they should not be taken in a limiting sense. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be evident to one skilled in the art, however, that the present disclosure may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate description of the present disclosure. 
     Referring initially to  FIG. 1 , a sediment trap  100  (also called a drip leg) is provided, wherein the sediment trap is configured to entrain substantial contamination associated with conventional compressed air, such as raw compressed air (e.g., unfiltered air) typically provided by one or more air compressors in a factory environment. Exemplary contaminants may include any debris, scale, dirt or other large particles, as well as liquids such as water and oil. The sediment trap  100  of  FIG. 1 , for example, comprises a chamber  102  having a top cap  104 , a bottom cap  106 , and a sidewall  108 , wherein the sidewall extends between the top cap and bottom cap. The top cap  104 , bottom cap  106 , and sidewall  108  generally enclose an interior region  110  of the chamber  102 . The top cap  104 , for example, may be selectively removable from the sidewall  108  of the chamber  102 , such as via one or more engagement members  112  (e.g., one or more screws, bolts, or one or more threads) between the top cap and the sidewall of the chamber. Further, the bottom cap  106  may be integral to the sidewall  108 , or may be a separate member operably coupled to the sidewall of the chamber  102 . 
     In accordance with one example, an inlet conduit  114  is operably coupled to the top cap  104  of the chamber  102 , wherein the inlet conduit is hollow and extends a predetermined distance  116  into the interior region  110  of the chamber along an inlet axis  118 . The predetermined distance  116 , for example, is at least one-quarter of a length  120  of the chamber  102 . In another example, the predetermined distance  116  is between one-quarter and two-thirds of the length  120  of the chamber  102 . The inlet conduit  114  fluidly couples the interior region  110  of the chamber  102  to an exterior region  122  of the chamber. The sidewall  108  of the chamber  102 , for example, is circular in cross-section when viewed along the inlet axis  118 . In the present example, the inlet axis  118  is centered with respect to the sidewall  108 , however other locations of the inlet conduit  114  and inlet axis  118  are contemplated as falling within the scope of the present disclosure. 
     According to another example, an outlet conduit  124  is operably coupled to the top cap  104 , wherein the outlet conduit has a first outlet axis  126  and second outlet axis  128  associated therewith. The outlet conduit  124 , for example, fluidly couples the interior region  110  of the chamber  102  to the exterior region  122  of the chamber. The first outlet axis  126 , for example, is generally parallel to the inlet axis  118 , wherein the second outlet axis  128  is offset from the first inlet axis. In the present example, the second outlet axis  128  is offset from the first inlet axis by approximately 90 degrees. In the present example, the outlet conduit  124  is defined in the top cap  104 . However, the present disclosure contemplates other examples, such as the outlet conduit  124  comprising a 90-degree elbow (not shown) operably coupled to a top surface  130  of the top cap  104 . Further, it should be noted that while the outlet conduit  124  is described as having a 90-degree bend, the present disclosure further contemplates other offset angles between the second outlet axis  128  and the first outlet axis  126 , with the preferred embodiment having an angle of approximately 90 degrees. 
     A clean-out conduit  132  is further provided, wherein the clean-out conduit is operably coupled to the bottom cap  106 . The clean-out conduit  132 , for example, further selectively fluidly couples the interior region  110  and exterior region  122  of the chamber  102 . The clean-out conduit  132 , for example, may be defined in the bottom cap  106 , or may be otherwise operably coupled thereto. In one example, the clean-out conduit  132  comprises a valve  134  configured to be selectively positioned in an open position and closed position, therein selectively fluidly coupling the interior region  110  and exterior region  122  of the chamber  102 . In the closed position, the valve  134  generally seals clean-out conduit  132  from the exterior region  122 , while in the open position, the valve is configured to evacuate sediment  136  deposited on the bottom cap  106  upon air pressure being applied to the inlet conduit  114 . In the present example, the clean-out conduit  132  is generally coaxial with the inlet conduit  114 , however the clean-out conduit may be offset from the inlet conduit. Further, as illustrated, the bottom cap  106  is beveled downward toward to the clean-out conduit  132  to aid in funneling, as will be discussed infra. 
     In accordance with another exemplary aspect of the present disclosure, an air preparation apparatus  150  is provided in  FIG. 2 , wherein the air preparation apparatus comprises the sediment trap  100  of  FIG. 1 . As illustrated in  FIG. 2 , the air preparation apparatus  150  further comprises one or more supplemental air preparation apparatuses  152 , wherein the outlet conduit  124  is further fluidly coupled to the one or more supplemental air preparation apparatuses. The one or more supplemental air preparation apparatuses  152 , for example, comprise one or more of an electrically-operated on/off valve, a manually-operated on/off valve, a soft start valve, a distribution module, a branch module, a pressure regulator, an electronic pressure regulator, a particulate filter, a coalescing filter, and a water separator. 
     Advantageously, the present disclosure provides the second outlet axis  128  of the outlet conduit  124  as coaxial with an inlet  154  to one or more of the one or more supplemental air preparation apparatuses  152 . As such, the one or more supplemental air preparation apparatuses  152  are positioned downstream of the sediment trap  100  in an advantageous manner, wherein a footprint of the air preparation apparatus  150  is minimal. According to another example, the inlet conduit  114  is configured to connect to a source of pressurized air  156 , such as an air compressor, or the like. 
     As illustrated in  FIG. 1 , unconditioned pressurized air  158  enters the sediment trap  100  through the inlet conduit  114 , whereby relatively large contaminants  160  gather on the bottom cap  106  due to gravity. The valve  134  of the clean-out conduit  132  can be selectively opened to remove the settled contaminants  160  to a waste container  162 . Due, at least in part, to a location of the outlet conduit  124  being higher than enclosed volume of the chamber  102 , substantially greater amounts of contaminant removal is attained by the sediment trap  100  of the present disclosure, as compared to conventional sediment traps. Additionally, the 90-degree offset between the second outlet axis  128  and the first outlet axis  126  provides an additional bend  166  in the paths  164  taken by the contaminants during the flow of air through the sediment trap  100 . As such, the present disclosure provides a four- to ten-fold increase in filtering capabilities over conventional sediment traps, thus providing an increased interval between maintenance of the sediment trap. 
       FIGS. 3 and 4  illustrate additional examples in accordance with the present disclosure. As illustrated in  FIGS. 3 and 4 , the inlet conduit  114  is operably coupled to the top cap  104  of the chamber, wherein the inlet conduit fluidly couples the interior region  110  of the chamber  102  to the exterior region  122  of the chamber along the inlet axis  118 . The outlet conduit  124  of the example of each of  FIGS. 3 and 4  is defined in the top cap  104  of the chamber  102 , wherein the outlet conduit further fluidly couples the interior region  110  of the chamber to the exterior region  122 , and wherein the outlet conduit defines the first outlet axis  126  and second outlet axis  128 . The first outlet axis  126  is spaced a predetermined distance  168  from the inlet axis  114  and is generally parallel to the inlet axis. As illustrated in  FIG. 3 , the inlet conduit extends into the interior region  110  of the chamber  102  between one-quarter and two-thirds of the length  120  of the interior region of the chamber.  FIG. 4 , on the other hand, illustrates the outlet conduit  124  extends into the interior region  110  of the chamber  102  between one-quarter and two-thirds of the length  120  of the interior region of the chamber. 
     Although the disclosure has been shown and described with respect to certain aspects, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (systems, devices, assemblies, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure that performs the function in the herein illustrated exemplary aspects of the disclosure. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several aspects, such feature may be combined with one or more other features of the other aspects as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising.”