Separation element of liquid separator, separation medium, liquid separator, and method for producing separation element

A liquid separator for separating liquid from an aerosol, the separation element comprising:

• a housing that has
• at least one aerosol inlet for the aerosol;
• at least one gas outlet for gas liberated from the liquid
• at least one separation element, comprising:
• at least one separation medium adapted to separate liquid for a gaseous fluid, the separation medium arranged in at least one medium layer extending circumferentially about an element axis;
• wherein at least one medium layer of at least one separation medium has, at a radially inward circumferential surface thereof relative to the element axis, a plurality of channel-shaped indentations extending axially to the element axis at least with one directional component;
• wherein axial as used herein is a direction parallel to the element axis;
• wherein radial as used herein is a direction traverse to the element axis:
• wherein the at least one separation medium has a specific minimum bend radius at which the at least one separation medium can be cylindrically wound relative to the element axis without producing kinks or bends forming channel-shaped indentations into a radial inward circumferential surface of the at least one medium layer;
• wherein the at least one medium layer is wound about the element axis, having a radially inner side of the at least one separation medium defining an inner diameter of the separation element;
• and
• wherein the specific minimum bend radius of the at least one separation medium is greater than the inner diameter of the separation element, producing kinks or bends into the radial inward inner circumferential surface of the at least one medium layer, the kinks or bends compressing material of the at least one medium layer between the radial inward circumferential surface and a radial outward circumferential surface of the at least one medium layer at the kinks or bends, forming the plurality of channel-shaped indentations into the deformed radial inward circumferential surface of the at least one medium layer;
• wherein the at least one separation medium is configured and adapted to separate oil from an air/oil fluid stream of a crankcase ventilation system of an internal combustion engine or a compressor;
• and
• wherein the separation medium is bent with a bend radius that is smaller than a specific minimum bend radius of the at least one separation medium;
• wherein the at least one separation element is arranged in the housing such that the aerosol flows through the at least one separation medium radially outwardly from radially inward or radially inwardly from radially outward relative to the element axis;
• wherein the element axis extends vertically in space in the normal operational orientation at least with one directional component;
• and
• wherein the at least one medium layer of the at least one separation medium has, on a radially inward circumferential surface relative to the element axis, at least one channel-shaped indentation of the plurality of channel-shaped indentations extending axially to the element axis at least with one directional component, in order to realize at least one channel for separated liquid.

A method for producing a separation element of a liquid separator, comprising the steps of:

• providing a separation medium realized as a medium web;
• wherein the at least one separation medium has a specific minimum bend radius at which the at least one separation medium can be cylindrically wound relative to the element axis without producing kinks or bends forming channel-shaped indentations into a radial inward circumferential surface of the at least one medium layer;
• winding the separation medium circumferentially around an element axis at a radius smaller than the specific minimum bend radius, producing kinks or bends into the radial inward inner circumferential surface;
• compressing material of the at least one medium layer between the radial inward circumferential surface and a radial outward circumferential surface of the at least one medium layer at the kinks or bends;
• forming a plurality of channel-shaped indentations into the radial inward circumferential surface at the kinks or bends;
• wherein the plurality of channel-shaped indentations are configured to receive separated liquid.