Single-Use Disc Filter Element With Integrated Framework
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Solution Overview
Problem
Conventional filter elements for disc filters are complex, heavy, and costly to manufacture and replace, with multiple components requiring intricate fastening and leading to potential leakage and reduced capacity due to their design.
Innovation Solution
A filter element with a permanently joined framework and filter cloth, manufactured from polymeric materials, featuring passages at the edges for liquid communication and a single fastening organ, allowing for easier assembly, replacement, and reduced weight, which facilitates efficient filtration and increased capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional filter elements use multiple components (frame, filter cloth, lid, fastening organs), then the filter element can be assembled and disassembled for maintenance, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the frame, filter cloth, and lid into a single integrated filter element component. The filter cloth is permanently joined to the framework, eliminating the need for separate fastening organs and multiple assembly steps. This merging reduces the number of components while maintaining the functionality of filter cloth replacement by simply removing the entire integrated element.
2Ease of repair
If conventional filter elements use multiple components with intricate fastening, then the filter cloth can be replaced, but the time and effort for replacement increase
Solution Approach 1:
By integrating the filter cloth permanently to the framework as a single component, the patent eliminates the time-consuming process of fastening and unfastening multiple parts. The filter element can be replaced as one unit, significantly reducing maintenance time while maintaining the ability to replace the filter cloth.
3Ease of manufacture
If conventional filter elements are made with multiple components, then assembly is possible, but the weight of the filter element increases
Solution Approach 1:
The patent merges multiple components into a single integrated filter element, eliminating the weight of fastening organs, seals, and other connecting hardware. The integrated design reduces the total weight while maintaining assembly capability through the permanent joining of the filter cloth to the framework during manufacturing.
4Ease of manufacture
If conventional filter elements have multiple components requiring fastening, then the structure can be assembled, but leakage risk increases at connection points
Solution Approach 1:
By permanently joining the filter cloth to the framework as a single integrated component, the patent eliminates all connection points where leakage could occur. The integrated design removes seals, gaskets, and fastening organs that create potential leakage paths, thereby improving reliability while maintaining manufacturing capability.
5Strength
If conventional filter elements use heavy materials and complex structures, then the structural strength is sufficient, but the capacity of the disc filter is reduced
Solution Approach 1:
The integrated filter element design reduces the overall weight and complexity of each filter component. This weight reduction allows for increased disc filter capacity by enabling more filter elements to be arranged on the rotor shaft or allowing for larger filter surface areas within the same weight constraints, thereby improving productivity.
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
The solution results in a lightweight, cost-efficient filter element that is simpler to manufacture and replace, reduces leakage risk, and enables a more compact disc filter design with higher capacity, as well as easier disposal.
Implementation Method 1
The filter element comprises a framework or structure carrying filter cloth on both side surfaces... Particles in the liquid are separated on the inside of the filter cloth
Implementation Method 2
The passages on the edges cause liquid and gas to flow between the filter elements during rotation of the filter discs
Implementation Method 3
Particles separated on the inside of the filter cloth are rinsed away with the help of spray nozzles placed so that the jets of liquid from the nozzles hit the outside of the filter cloth
Data Source
Figure 1
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Figure 4
AI summary
A filter element (2) for use in a disc filter (1), wherein a plurality of filter elements (2) are arranged on a rotor shaft (3) in a manner allowing liquid communication between the inside (4) of the filter elements (2) and the inside (5) of the rotor shaft (3), for the filtering of liquids. The filter element (2) includes a framework (6) carrying a filter cloth (7) on both its side surfaces (8), wherein the framework (6) and the filter cloth (7) are permanently joined forming a single use filter element (2) and the filter element has at least one passage (21) in each edge (22) for liquid communication between the inside (4) of adjacent filter elements. A disc filter (1) including a single use filter element (2) is also provided.