Deep Corrugated Filter Media Pack with Varying Channel Geometry
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Solution Overview
Problem
Corrugated filter media loses effectiveness at pleat depths greater than 50-75 mm, as increased pleat density is offset by channel flow losses, and is susceptible to collapse due to dust cake formation, with masked media area reducing filtration efficiency.
Innovation Solution
A filter media pack is created by scoring and folding a sheet to form deeply corrugated channels with varying upstream and downstream openings, using a zig-zag folding pattern and tacking adhesive to maintain structure and maximize flow area, allowing for increased dust-holding capacity and improved filtration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pleat depth is increased to support lower pleat densities, then filtration capacity is improved, but channel flow losses increase and effectiveness decreases
Solution Approach 1:
The patent transitions from conventional 2D pleated filter media to a 3D folded structure with varying channel depths. By creating channels with different depths (deeper in the middle, shallower at edges) and using multi-directional folding, the design increases filtration capacity in the vertical dimension while maintaining optimized flow paths that prevent excessive pressure drops, thus resolving the contradiction between filtration capacity and flow losses.
Solution Approach 2:
The filter media employs non-uniform channel depths where central channels are deeper and edge channels are shallower. This local variation optimizes flow distribution across the filter face, ensuring that high-flow central regions have deeper channels for capacity while edge regions maintain shallower channels for flow control, thereby balancing filtration capacity with flow loss prevention.
2Strength
If rounded corrugations are used, then media area is reduced, but structural support against collapse is improved
Solution Approach 1:
The patent utilizes curved score lines and rounded fold axes in the filtering structure. These curved elements provide structural reinforcement that resists collapse under dust load while the overall folded geometry maintains large open flow areas. The curvature is strategically placed at fold lines rather than masking media surfaces, thus achieving structural support without sacrificing useful media area.
3Strength
If hot melt spacing and media embossing are used, then structural support is improved, but useful media area is masked off
Solution Approach 1:
The patent removes the need for hot melt spacing and media embossing by using self-supporting folded geometry. The multi-directional folding creates inherent structural rigidity through geometric interlocking, eliminating the requirement for additional support elements that would mask media area. The structure supports itself through its folded configuration rather than requiring external reinforcement.
4Ease of manufacture
If classical corrugated media is used, then manufacturing is simplified, but the media is susceptible to collapse as dust cake forms
Solution Approach 1:
The filter media is divided into multiple folded layers with varying channel depths and orientations. This segmentation creates a hierarchical structure where outer layers protect inner layers, and the multi-level folding provides progressive structural support. The segmented design maintains manufacturing simplicity through systematic folding while dramatically improving collapse resistance compared to single-layer classical corrugated media.
Data Source
AI summary
Filter media packs that utilizes a zig-zag folding pattern on deeply corrugated filter media are described. The filter media is scored, folded, and secured into position to form the filter media pack. The filter media pack may be secured using a self-supporting structure (e.g., via tacking adhesive used to secure adjacent folds). The filter media pack contains unique features to optimize filtration performance, such as maximized inlet and outlet face flow areas. In some arrangements, the filter media pack exhibits improved flow characteristics and dust-holding capacity via upstream and downstream channels that have different cross-sectional shapes and/or sizes. The upstream and downstream channels may comprise, for example, circular, diamond shaped, or fish-scale shaped openings.