Air Control Valve Filter Assembly for Particle Capture and Airflow

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Solution Overview

Problem

Conventional filters used in air control valves either become clogged quickly due to small openings, requiring frequent changes, or fail to capture sufficient particles when openings are large, leading to inadequate protection and potential airflow restriction.

Innovation Solution

A filter assembly with a dual-layer filter medium and an inlet tube design that prevents particulate matter from falling into the inlet passageway during replacement, ensuring effective particle capture and maintaining airflow while allowing for easy filter maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If filter openings are made small to capture particles, then particle capture effectiveness is improved, but filter clogs quickly requiring frequent changes and airflow is restricted

Engineering Contradiction:

Improveparticle capture effectivenessVSAvoidairflow rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The filter medium is divided into multiple layers with different opening sizes. The first layer has smaller openings for capturing smaller particles, while the second layer has larger openings to maintain airflow. This segmentation allows each layer to perform its specific function, resolving the contradiction between particle capture and airflow restriction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the filter assembly have different properties. The first layer is positioned closer to the inlet where particle concentration is highest and provides finer filtration, while the second layer provides coarser filtration and maintains airflow. This local differentiation optimizes both particle capture and airflow simultaneously.

Inventive Principle:

Principle #3Local quality

2Productivity

If filter openings are made large to maintain airflow, then airflow restriction is reduced, but particle capture effectiveness decreases

Engineering Contradiction:

Improveairflow rateVSAvoidparticle capture effectiveness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The filter is segmented into two layers with progressively larger openings from inlet to outlet. This allows the system to capture particles effectively in the first layer while maintaining adequate airflow through the second layer with larger openings, resolving the contradiction between airflow and particle capture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a single layer with compromised performance, the solution adds a dimensional aspect by creating a multi-layer structure. This vertical arrangement of layers with different opening sizes allows simultaneous optimization of both airflow and particle capture that cannot be achieved with a single layer.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of repair

If filter housing is removed for replacement, then filter maintenance is enabled, but particulate matter falls into the inlet passageway

Engineering Contradiction:

Improvefilter replacement accessibilityVSAvoidcontaminant intrusion into inlet

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The inlet tube is designed to extend into the inlet passageway before filter replacement begins. This preliminary positioning of the inlet tube creates a protective barrier that prevents particulate matter from falling into the inlet during the subsequent filter removal and replacement operations, enabling maintenance without contamination.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The inlet tube acts as an intermediary protective element between the inlet passageway and the filter housing. During filter replacement, this intermediate structure prevents direct exposure of the inlet to falling particulates, allowing maintenance personnel to work safely without contaminating the inlet area.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 filter assembly effectively blocks particles from reaching critical components, maintains airflow, and allows for filter replacement without contaminant intrusion, balancing particle capture with airflow restriction within desired operating parameters.

Implementation Method 1

The filter medium filters particulates from the airflow communicated to the control valve

Methodology Applied

Scientific EffectPhysical barrier filtration: Filter (physical)

Data Source

PatentEP2412421B1Air control valve

Publication Date: 2021.01.27 HAMILTON SUNDSTRAND CORP

Figure 1~2
Figure 3~4

AI summary

A filter assembly (26) prevents particles from entering a control valve and defines an airflow path between an inlet (28) and outlet (30). An inlet tube (36) extends from the inlet (28) and defines an inlet passage into a filter housing (38). Openings (42) within the inlet tube (36) open into an interior space of a filter housing (38). An outer housing (44) defines a cavity within which the filter housing (38) is secured. The filter housing (38) includes an open top portion that engages a cap (50) that covers and seals the outer housing (44). The cap (50) holds the filter housing (38) to prevent movement of the filter housing (38).