Curved Filter Core Geometry for Usable Pleat Area
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Solution Overview
Problem
Existing filter configurations with circular or rectangular central cores densely pack pleats near the core, masking portions of the filter material and reducing the usable filtration area.
Innovation Solution
A cylindrical filter element with a convex curved central core and varying pleat depths, where pleats extend radially from an outer periphery and inner tips are adjacent to the core, allowing for a more oval or elliptical cross-section that maximizes usable filter material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pleats are densely packed near the central core to increase filtration area, then the amount of filter material is increased, but portions of the filter material are masked and become unusable
Solution Approach 1:
The core element employs an asymmetric cross-sectional shape with a convex curved central portion and tapered ends, creating non-uniform spacing between the core and outer periphery. This asymmetric geometry allows pleats to be distributed more evenly, preventing dense packing and masking near the core while maximizing the usable filtration area throughout the filter element.
Solution Approach 2:
The core element features a convex curved central portion rather than a sharp-cornered geometry. This curvature creates gradual transitions in spacing around the core, allowing pleats to extend uniformly from the core surface without creating concentrated dense regions that would mask filter material. The curved surface optimizes the radial distribution of pleats to maximize usable filtration area.
2Adaptability or versatility
If pleats extend radially from a central core to fit within a cylindrical opening, then the filter fits the geometry, but pleats are densely packed near the core masking portions of filter material
Solution Approach 1:
The core element uses an asymmetric cross-section with a convex curved central portion and tapered ends that creates non-uniform radial spacing. This asymmetric design maintains compatibility with cylindrical openings while optimizing pleat distribution to prevent masking and maximize the quantity of usable filter material within the given cylindrical geometry.
Solution Approach 2:
The core geometry varies locally along its circumference, with the convex curved central portion providing greater spacing in certain regions and tapered ends providing different spacing in other regions. This local variation in geometry optimizes pleat distribution across different zones, ensuring uniform pleat spacing and maximizing usable filter material throughout the entire filter element.
Data Source
AI summary
A cylindrical filter element including a central longitudinal axis extending along a height of the filter element, a core element extending along at least a portion of the height of the filter element and having a convex curved central portion extending from a first end to a second end to define a width of the core element, wherein the convex curved central portion has a maximum height through the central longitudinal axis that is larger than a height of at least one of the first and second ends, and filter material including a plurality of pleats extending radially from an outer periphery of the core element, wherein an outer cylindrical periphery of the filter material is defined by an outer pleat tip of each of the plurality of radially extending pleats, and wherein an inner pleat tip of each radially extending pleat is adjacent to the core element.