Corrugated Filter Media Pack for High-Pressure Liquid Filtration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing axial flow filter elements do not perform well in high pressure liquid filtration applications due to channel collapse under pressure drop and high contaminant removal efficiency requirements, especially when high contaminant removal efficiency is required, due to the inability to accommodate the structural integrity of the channels.
Innovation Solution
The use of a corrugated support sheet made from a different material than the filtration sheet, which provides structural support and directs fluid flow, while being less permeable than the filtration sheet, combined with multiple filtration stages of varying permeability to enhance filtration efficiency and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the filter uses a conventional flat media structure, then the manufacturing is simple, but the media surface area is limited and pressure drop increases
Solution Approach 1:
The filter media is segmented into multiple corrugated channels instead of a single flat surface. The corrugated support sheet creates multiple parallel flow paths (channels) that increase the total media surface area available for filtration while maintaining a compact overall structure.
Solution Approach 2:
The flat two-dimensional media is transformed into a three-dimensional corrugated structure. The corrugations add vertical dimensionality to the media pack, allowing fluid to flow through multiple levels and significantly increasing the effective filtration surface area without proportionally increasing the filter housing volume.
2Strength
If thicker filtration sheets are used to increase structural strength, then the media strength improves, but the pressure drop increases and filtration efficiency decreases
Solution Approach 1:
The filter employs a composite structure combining a corrugated support sheet (providing mechanical strength and structural integrity) with filtration sheets (providing filtration function). The support sheet's corrugated geometry provides structural reinforcement without requiring the filtration sheets to be excessively thick, thus maintaining low pressure drop and high filtration efficiency.
Solution Approach 2:
The corrugated support sheet acts as an intermediary structural element that bears the mechanical loads and provides channel formation, allowing the filtration sheets to be thinner and more efficient. The support sheet mediates between the need for structural strength and the need for low pressure drop by assuming the structural function separately from the filtration function.
3Reliability
If the filter operates at high pressure, then the contaminant removal capability improves, but the pressure drop through the media increases
Solution Approach 1:
The high pressure load is segmented and distributed across multiple parallel corrugated channels rather than concentrated in a single path. This segmentation allows the system to maintain high contaminant removal capability through multiple filtration stages while keeping the pressure drop in each individual channel manageable.
Solution Approach 2:
The corrugated geometry with its curved surfaces and optimized flow paths reduces flow resistance compared to flat media. The curved corrugation profiles guide fluid flow more efficiently, reducing turbulence and pressure drop while maintaining effective filtration under high-pressure operating conditions.
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 increases the media surface area and structural strength, allowing for improved filtration efficiency and extended service life under high pressure conditions, while maintaining low pressure drop across the filter element.
Implementation Method 1
The corrugated support sheet and the filtration sheet form a plurality of channels that are alternately sealed on opposing ends of the media pack
Implementation Method 2
a filtration sheet and a corrugated support sheet that is coupled to the filtration sheet... to remove such particulate matter or other contaminants
Implementation Method 3
The corrugated support sheet is made from a different material than the filtration sheet... provides structural support
Data Source
AI summary
A media pack includes a filtration sheet and a support sheet that is made from a different material than the filtration sheet. The filtration sheet is coupled to the support sheet. The support sheet is corrugated such that, together, the filtration sheet and the support sheet form a plurality of channels. The channels are alternately sealed on opposing ends of the media pack. In one embodiment, the permeability of the support sheet is less than a permeability of the filtration sheet.