Angled Pleated Filter Element for High Density Filtration
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Solution Overview
Problem
Existing pleated filter elements face inefficiencies in utilizing space and achieving high filtration efficiency due to symmetrical arrangements and parallel pleat orientations, which limit their effectiveness in filtering both liquid and gaseous fluids.
Innovation Solution
The filter element comprises two pleated sections with pleats positioned at an angle relative to each other, forming connected clean chambers that allow fluid to flow through in different directions, optimizing pleat density and space utilization, and can be configured with open or closed rim sides and support structures for enhanced stability and filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pleated sections are arranged with parallel pleats in symmetrical configuration, then manufacturing is simple, but space utilization and filtration efficiency are limited
Solution Approach 1:
The patent applies asymmetry by arranging pleated sections at angles of 60°, 90°, or 120° relative to each other instead of parallel symmetrical arrangements. This angular configuration increases pleat density and optimizes space utilization within the filter housing, thereby improving filtration efficiency while maintaining manufacturing feasibility through standardized angular relationships.
Solution Approach 2:
The patent transitions from two-dimensional parallel pleat arrangements to three-dimensional angular configurations. By orienting pleated sections in different spatial dimensions at specific angles, the design maximizes the use of available filter volume, allowing more pleats to be packed into the same space without increasing manufacturing complexity.
2Productivity
If multiple separate outflow openings are provided for each clean chamber, then fluid discharge is efficient, but device complexity increases
Solution Approach 1:
The patent merges multiple separate outflow openings into a single common outflow opening that serves all clean chambers. The clean chambers are fluidically connected through internal passages, allowing purified fluid from multiple pleated sections to converge and exit through one opening. This reduces structural complexity while maintaining efficient fluid discharge through the shared outlet.
3Productivity
If pleat density is increased to maximize filtration, then filtration efficiency improves, but structural stability decreases
Solution Approach 1:
The patent segments the filter into multiple pleated sections with fewer pleats per section compared to high-density single-section designs. Each section is structurally supported independently, and the sections are arranged at angles to distribute mechanical loads. This segmentation maintains high overall filtration efficiency through increased total pleat surface area while preserving structural stability through distributed support.
Solution Approach 2:
The patent applies different pleat densities and configurations to different local regions or sections of the filter. Each pleated section can be optimized for its specific location and flow requirements, allowing high pleat density where filtration is prioritized while maintaining adequate structural support in load-bearing areas. The angular arrangement of sections creates local structural reinforcement at the joints.
Data Source
AI summary
A filter element is provided with a folded bellows that has a first pleated section with parallel arranged first pleats and a second pleated section with parallel arranged second pleats. The first pleats of the first pleated section are positioned at an angle relative to the second pleats of the second pleated section. The end face edges of the first pleats of the first pleated section adjoin a first clean chamber. The end face edges of the second pleats of the second pleated section adjoin a second clean chamber. The second clean chamber is delimited by a longitudinal side of an edge-side pleat of the first pleated section. The first and second clean chambers are connected to each other. A filter insert with such a filter element is provided.