Alternating Spacer Filter Media Construction for Reduced Pressure Drop
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Solution Overview
Problem
Conventional filter elements with pleated or fluted media constructions suffer from increased pressure drop, reduced contaminant holding capacity, and turbulence in air/gas filtration systems due to pleating or fluting processes that damage the media and restrict fluid flow, leading to less-than-expected performance.
Innovation Solution
A filter media construction featuring alternating layers of spacers and filter media coiled around a core to form continuous, contiguous, and separated axial flow channels, eliminating pleating or fluting and maintaining uniform flow channels for reduced pressure drop and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If pleated or fluted filter media constructions are used, then filter media area can be packaged in a given filter element size, but pressure drop increases and fluid flow becomes turbulent
Solution Approach 1:
The filter media is segmented into multiple pleated layers alternating with spacer layers, creating distinct flow channels that separate clean and dirty sides. This segmentation maintains large filter media area while organizing flow paths to reduce turbulence and pressure drop.
Solution Approach 2:
Spacer layers are introduced as intermediary elements between filter media layers. These spacers create uniform flow channels, prevent media-to-media contact, and guide fluid flow in a streamlined manner, reducing turbulence and pressure drop while maintaining extensive filter media area.
2Ease of manufacture
If pleating or fluting processes are applied to filter media, then filter element construction is achieved, but filter media properties are deteriorated and mechanical damage occurs
Solution Approach 1:
The construction process segments the filter element into distinct alternating layers of filter media and spacers. This layered segmentation allows gentle assembly without subjecting the filter media to damaging pleating or fluting mechanical forces, preserving media integrity and performance.
Solution Approach 2:
Spacer layers serve as protective intermediary elements during assembly, preventing direct mechanical contact and damage between filter media layers. The spacers facilitate gentle construction while maintaining the required structural form, preserving filter media reliability.
3Shape
If pleated filter media constructions are used, then filter element form is created, but contaminant holding capacity is reduced due to flow restrictions
Solution Approach 1:
The filter element is segmented into alternating layers of filter media and spacers, creating a structured form with multiple flow channels. This segmentation maintains the required filter element shape while maximizing the active filter media area, thereby increasing contaminant holding capacity.
Solution Approach 2:
Spacer layers act as intermediaries that maintain uniform flow channel geometry and prevent flow restrictions. By ensuring streamlined flow through the spacer-mediated channels, the filter media can operate at full capacity, maximizing contaminant holding ability.
4Ease of operation
If conventional pleated filter media constructions are used, then sealing and fitment features can be incorporated, but turbulence and noise are generated in air/gas flow
Solution Approach 1:
The filter element is constructed with segmented alternating layers of filter media and spacers, creating a structured form that naturally incorporates sealing surfaces and fitment features. This segmentation achieves the required ease of operation while the streamlined flow channels minimize turbulence and noise generation.
Solution Approach 2:
Spacer layers serve as intermediary structural elements that create uniform, streamlined flow channels. These spacer-mediated channels reduce flow turbulence and noise while the overall segmented construction maintains ease of sealing and fitment operations.
Data Source
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AI summary
The present disclosure discloses a filter media construction wherein at least two layers of a substantially open spacer and at least two layers of a filter media/material are combined in an alternating sequence and coiled around a core to form at least two distinct, continuous or segmented, coil-shaped fluid flow channels that are contiguous but separated by the filter media in radial direction and extend axially from an inlet side to an outlet side of the filter media construction preventing direct fluid flow between the clean and dirty sides of the filter media construction. The spacer maintains substantially uniform width of flow channels in flow direction providing substantially uniform fluid flow. One flow channel is closed to fluid flow at the inlet side forming the clean side and the other flow channel is closed to fluid flow at the outlet side forming the dirty side of the filter media construction.