Diamond-pleated filter media reversible expansion
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Solution Overview
Problem
Existing pleated filters do not efficiently utilize space and maintain filtration performance when expanded or compacted, leading to suboptimal filtration efficiency and ease of use.
Innovation Solution
The development of diamond-pleated filter media, which features front and rear pleats with offset junctions between adjoining front pleat walls, allowing for reversible expansion and compactation while maintaining filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional pleated filters are expanded to increase filtration area, then filtration capacity is improved, but structural stability and space utilization deteriorate
Solution Approach 1:
The filter media is divided into multiple diamond-shaped cells formed by pleats, with each cell being a discrete structural unit. This segmentation allows the filter to expand into a stable three-dimensional configuration with multiple triangular faces, distributing mechanical stresses across numerous small units rather than relying on a single large structure, thereby maintaining structural stability while achieving large total filtration area
Solution Approach 2:
The filter structure transitions from a two-dimensional planar configuration to a three-dimensional diamond-pleated configuration. The pleats create depth and volume, forming a corrugated structure that occupies three-dimensional space. This dimensional transition allows the filter to achieve greater filtration area within the same footprint while the three-dimensional geometry inherently provides structural rigidity and stability
2Volume of moving object
If pleated filters are compacted to save space, then space utilization is improved, but filtration efficiency deteriorates
Solution Approach 1:
The diamond-pleated filter structure is designed to be dynamically transformable between compact and expanded states. The pleated configuration allows the filter to be compressed into a thin package for storage and shipping, then expanded in-situ within the HVAC system to achieve full filtration capacity. This dynamic capability enables the filter to occupy minimal space during storage while providing full filtration performance during operation
Solution Approach 2:
The filter media is folded into a compact nested configuration where the diamond pleats are collapsed into a thin package. This nesting allows multiple filters to be stored in sequence within a compact form factor, similar to nested dolls, while maintaining the ability to expand each filter to its full functional size when installed and activated
3Adaptability or versatility
If junctions are added to create diamond-pleated structure, then reversible expansion and compactation are improved, but device complexity increases
Solution Approach 1:
The diamond-pleated structure employs asymmetric folding patterns where pleats are folded at specific angles and orientations to create the diamond configuration. This asymmetric design, with pleats folded in alternating directions and at specific geometries, enables the structure to expand and contract reversibly along specific axes while maintaining structural integrity, providing adaptability without requiring complex mechanical components
Data Source
AI summary
A pleated filter media comprising front pleats and rear pleats, with at least some of the front pleats having junctions at which local areas of adjoining front pleat walls of the front pleat are frontally joined together. The junctions may be at discrete locations that are spaced along a pleat direction of the front pleats. For any two nearest-neighbor front pleats, the junctions of one of the front pleats may be offset, along the pleat direction, from the junctions of the other front pleat.