Coalescing Filter Element With Structurally Separate Layer
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Solution Overview
Problem
Conventional coalescing filters with external support jackets face manufacturing challenges, such as fitting issues with solid materials and efficiency loss due to elastic material stretching, and often have reduced filter efficiency compared to integrated coalescing designs.
Innovation Solution
A filter element design where the coalescing layer is structurally separate from the filter medium, with minimal contact (<10% of its inside surface), allowing the coalescing layer to be unpleated while the filter medium is pleated, and surrounded by a lattice-like outer support jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the coalescing material is made solid to maintain structural integrity, then the support strength is improved, but the fitting difficulty and manufacturing complexity increase
Solution Approach 1:
The filter element is divided into distinct functional layers: a pleated filter medium and a separate coalescing layer. This segmentation allows each layer to be optimized independently - the filter medium provides structural support when pleated, while the coalescing layer performs its function without bearing structural loads, eliminating fitting difficulties.
Solution Approach 2:
An outer support jacket is introduced as an intermediary structural element that surrounds both the filter medium and coalescing layer. This jacket assumes the mechanical support function, allowing the coalescing layer to be placed loosely inside without requiring precise fitting or structural integrity, thus resolving the manufacturing difficulty.
2Ease of manufacture
If elastic material is used to ease fitting during manufacture, then the ease of manufacture is improved, but stretching during operation leads to loss of filtering efficiency
Solution Approach 1:
The filter element is divided into distinct functional layers: a pleated filter medium and a separate coalescing layer. This segmentation allows each layer to be optimized independently - the filter medium provides structural support when pleated, while the coalescing layer performs its function without bearing structural loads, eliminating fitting difficulties.
Solution Approach 2:
An outer support jacket is introduced as an intermediary structural element that surrounds both the filter medium and coalescing layer. This jacket assumes the mechanical support function, allowing the coalescing layer to be placed loosely inside without requiring precise fitting or structural integrity, thus resolving the manufacturing difficulty.
3Device complexity
If the coalescing layer is integrated with the filter medium, then the device complexity is reduced, but the filter efficiency decreases
Solution Approach 1:
The filter element is divided into distinct functional layers: a pleated filter medium and a separate coalescing layer. This segmentation allows each layer to be optimized independently - the filter medium provides structural support when pleated, while the coalescing layer performs its function without bearing structural loads, eliminating fitting difficulties.
Solution Approach 2:
Different regions of the filter element have specialized functions: the pleated filter medium provides structural support and initial filtration, while the separate coalescing layer provides the coalescing function. This local optimization of function leads to superior overall performance compared to integrated designs.
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
This design enhances filter efficiency by maintaining the coalescing function without being an integral part of the filter body, as measured by DIN ISO standards, using various materials like foam or polyester fiber fleece with glass fiber paper as filter media.
Implementation Method 1
The task of this coalescing jacket is to further unite the liquid or oil droplets caught by the actual filter material and to direct them to a common outlet
Implementation Method 2
an outer support jacket (4), which surrounds a filter medium (7) with a coalescing layer (5) which is essentially structurally separate therefrom
Data Source
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AI summary
The invention relates to a filter element for a coalescing filter, comprising an outer supporting structure, a coalescing layer and a filter medium, the coalescing layer being substantially structurally separate from the filter medium.