3D Filter Insert Layout for Uniform Particle Adhesion
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Solution Overview
Problem
Existing filter modules suffer from uneven particle adhesion due to abrupt airflow redirection, leading to inefficient particle capture and short module lifespan, with time-consuming and complex replacement processes.
Innovation Solution
A filter module design featuring transverse and longitudinal walls with offset openings that create a wave-like, laminar airflow, ensuring uniform particle adhesion and simplifying assembly by forming a stable three-dimensional structure without the need for additional fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the airflow is redirected abruptly in multiple directions within the filter module, then the airflow can pass through the filter structures, but the particle adhesion becomes unevenly distributed with the first chamber capturing the majority of particles
Solution Approach 1:
The patent applies curved surfaces and angled transitions instead of abrupt 90-degree redirects. The filter structures use inclined surfaces and curved airflow paths to guide air smoothly through the module, preventing sudden deceleration and ensuring uniform particle distribution across all chambers.
Solution Approach 2:
The patent creates a dynamic airflow pattern that adapts through the filter module using progressively angled openings and curved surfaces. This dynamic design allows the airflow to maintain velocity while changing direction gradually, ensuring consistent particle capture throughout the module rather than concentrating particles in the first chamber.
2Ease of manufacture
If multiple cleaning structures are arranged one behind the other within the hollow body, then the filter module can be assembled, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The patent combines multiple filter walls and cleaning structures into a single integrated hollow body structure. This merging eliminates the need to assemble multiple separate components, reducing assembly time from minutes to seconds while maintaining the multi-chamber configuration for effective particle capture.
Solution Approach 2:
The filter structures are pre-assembled and pre-positioned within the hollow body during manufacturing. The walls, openings, and cleaning structures are configured in their final positions before the module is sealed, eliminating the need for complex on-site assembly and ensuring proper alignment.
3Productivity
If the filter module is designed with multiple chambers and complex internal structures, then particle separation can be improved, but the module lifespan is reduced due to uneven particle accumulation
Solution Approach 1:
The curved surfaces and gradual transitions distribute particles uniformly across all chambers by preventing abrupt airflow deceleration. This ensures that each chamber accumulates particles at similar rates, extending the module's effective lifespan before replacement is needed.
Solution Approach 2:
The patent optimizes the angular parameters of the openings and internal surfaces to control airflow velocity and direction. By carefully selecting these geometric parameters, the module achieves both high particle separation efficiency and uniform particle distribution, maximizing operational lifespan.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves efficient and uniform particle separation with extended module lifespan, reducing assembly time to under 30 seconds and minimizing cake formation, while allowing for easy and cost-effective disposal.
Implementation Method 1
A wave-like, in particular laminar, flow can be generated from the inlet to the outlet
Implementation Method 2
A wave-like, in particular laminar, flow can be generated from the inlet to the outlet, causing particles from the airflow to be cleaned to adhere evenly to the filter element
Implementation Method 3
causing particles from the airflow to be cleaned to adhere evenly to the filter element
Data Source
Figure 1~3
Figure 4(a)~6
Figure 7(a)~8(b)
AI summary
The invention relates to a filter module for separating particles from contaminated air, comprising a receiving element which has an inlet side for admitting an airflow to be cleaned and an outlet side for discharging the cleaned airflow, said inlet side and outlet side being arranged opposite each other on the receiving element, and comprising a three-dimensional filter insert which is received in the receiving element, wherein the filter insert has at least two transverse walls which are arranged approximately parallel to each other, and each transverse wall has at least one opening. The openings of the transverse walls are vertically offset and/or overlap vertically such that the air flowing from the inlet side in the direction of the outlet side can be deflected onto different vertical levels through the openings. A wave-shaped airflow can be formed from the inlet side to the outlet side such that particles from the airflow to be cleaned are adhered in the filter insert in a uniformly distributed manner. The invention additionally relates to a method for operating such a filter module and to a method for assembling same.