Capillary Filter Element With Permeable Membrane For Reduced Vacuum Power
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Solution Overview
Problem
Existing filter elements are often heavy when wet, making them difficult to handle during maintenance and posing occupational safety risks, and they require heavy-duty vacuum pumps due to vacuum losses through cloth media, which is inefficient.
Innovation Solution
A filter element comprising a permeable membrane layer forming a capillary filter with a frame member that supports it, allowing for independent material selection based on part-specific requirements, resulting in a lightweight and durable design that minimizes air flow during cake drying and optimizes water flow during filtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cloth filter medium is used, then filtration can be performed, but heavy duty vacuum pumps are required due to vacuum losses through the cloth
Solution Approach 1:
The filter element is divided into distinct functional zones: a support structure (frame member) and a filter member with permeable membrane layer. This segmentation allows the support structure to provide mechanical strength while the filter member handles filtration, reducing overall material usage and vacuum losses compared to using thick cloth media throughout.
Solution Approach 2:
The filter member uses a permeable membrane layer that provides controlled porosity for efficient filtration. This porous structure allows liquid to pass through while retaining solids, and when combined with the capillary filter design, minimizes unnecessary air flow during cake drying, reducing vacuum pump power requirements.
2Use of energy by stationary object
If ceramic filter medium is used, then vacuum level is decreased and energy is saved, but the medium does not allow air to pass through when wetted due to capillary action
Solution Approach 1:
The filter element applies different properties to different parts: the filter member uses a permeable membrane with specific porosity for efficient liquid filtration, while the support structure provides mechanical strength. This local differentiation allows optimized performance for both energy efficiency and operational flexibility, including controlled air flow when needed.
Solution Approach 2:
The filter element combines a frame member (support structure) with a filter member containing a permeable membrane layer. This composite construction integrates materials with different properties - the frame provides structural integrity while the membrane provides filtration functionality with controlled porosity, achieving both energy efficiency and operational ease.
3Productivity
If traditional filter elements are used, then filtration is achieved, but they become heavy when absorbing liquid during use
Solution Approach 1:
The filter member uses a thin permeable membrane layer that provides effective filtration surface area while minimizing material volume and weight. This thin film approach allows the filter to process large volumes of liquid without the weight increase associated with thick cloth or dense ceramic media.
Solution Approach 2:
The composite structure of frame member plus filter member allows separation of functions: the frame provides minimal structural support weight, while the thin permeable membrane provides filtration capability. This composite design achieves high filtration productivity with minimal weight, even when the filter absorbs liquid during operation.
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 solution enables a filter element that is both lightweight and durable, reducing the need for heavy vacuum pumps and improving safety by minimizing air flow through the filter, while maintaining efficient water flow and energy savings.
Implementation Method 1
The ceramic filter medium, when wetted, does not allow air to pass through due to a capillary action. This decreases the necessary vacuum level, enables the use of smaller vacuum pumps and, consequently, yields significant energy savings.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A filter element (1) for a filter apparatus (2) comprises at least one filter member (3)and a frame member (4) arranged to support the at least one filter member (3) in such a manner that the internal cavity (12) is formed. The filter member (3) comprises a permeable membrane layer and has a first filter surface (9a) for receiving a pressure and directed towards an internal cavity (12) arranged inside the filter element (1), and a second filter surface (9b) for receiving solid particles filtered from a feed. The filter member (3) forms a capillary filter.