Disposable Filter Cartridge for High-Flow Filtration
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Solution Overview
Problem
Existing filtration systems for separating solid particles from liquids and gases are complex, costly, and require extensive cleaning and sterilization, making them inefficient for high-flow rate applications and difficult to scale up, especially in industries like food and biopharmaceuticals where quick product changeovers and minimized residual volumes are necessary.
Innovation Solution
A disposable filtration device featuring a pressure vessel with multiple flat filter elements arranged in a flexible plastic container, allowing for high filtration area per volume, easy assembly, and modular design, which can be compacted and recycled, eliminating the need for extensive cleaning and sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If traditional metallic filtration systems are used, then durability and reusability are improved, but cleaning and sterilization complexity increases
Solution Approach 1:
The patent implements a disposable filter cartridge system made of flexible plastic that is discarded after a single use, eliminating the need for complex cleaning and sterilization processes. The flexible plastic container with integrated filter elements can be disposed of after one filtration cycle, while the pressure vessel is reused. This resolves the contradiction by sacrificing reusability of the filter cartridge to dramatically reduce cleaning and sterilization complexity.
2Strength
If filter elements are made thicker for structural stability, then mechanical strength is improved, but residual volume increases
Solution Approach 1:
The patent uses thin flexible plastic films and shells to construct the filter cartridge, including the container wall and filter element supports. These thin flexible structures provide sufficient mechanical strength for the application while minimizing the volume occupied by structural components, thereby reducing the residual volume of suspension that remains after filtration. The flexibility allows the structure to collapse during compression without requiring thick rigid walls.
Solution Approach 2:
The patent changes the physical state and properties of the filter package by compressing it from a loose configuration to a compacted state. The flexible plastic structure allows the filter elements to be compressed together, reducing the residual volume significantly. This parameter change from loose to compacted state maintains structural integrity while minimizing wasted space.
3Productivity
If filtration area is increased, then filtration efficiency is improved, but device volume increases
Solution Approach 1:
The patent transitions from traditional horizontal filter element arrangement to a vertical stacking configuration where multiple flat filter elements are stacked one on top of another within the flexible plastic container. This dimensional change allows the filtration area to be increased by adding more filter elements in the vertical direction rather than expanding the horizontal footprint, thereby maintaining a compact device volume while achieving high filtration efficiency.
Solution Approach 2:
The patent implements a nested structure where multiple filter elements are stacked and nested within the flexible plastic container, with each filter element containing support grids and filter media nested within the container structure. This nesting arrangement maximizes the filtration area within a compact volume by efficiently utilizing the three-dimensional space.
4Productivity
If filter elements are arranged in parallel suspension, then filtration area per volume is improved, but compression difficulty increases
Solution Approach 1:
The patent uses flexible plastic materials for the container and filter element construction, which inherently possess compressibility. The flexible plastic container can be compressed to reduce residual volume, and the filter elements themselves are made with flexible support structures that allow compression without damage. This flexibility resolves the contradiction by enabling both high filtration area per volume through parallel suspension arrangement and ease of compression for compacting the filter package.
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 provides high filtration efficiency with low investment costs, reduced residual volume, and simplified product changeovers, enabling cost-effective filtration with high flow rates and minimized cleaning costs, particularly suitable for industries requiring sterile conditions.
Implementation Method 1
Device for the separation of solid particles from liquids and gases... consisting of a pressure vessel with suspended filter elements
Data Source
AI summary
In a device for separating solid particles from liquids and gases in flexible disposable plastic containers, a plurality of filter elements, consisting of flat, elongate support grids with filtrate drain channels and a covering, all-round closed filter medium, are connected to form a filter package and enclosed by a flexible plastic container. This disposable filter system is operated in a pressure vessel and can be compressed there by applying an external pressure in such a way that the residual volume of the suspension is considerably reduced. As a result of the stable design, backwashing of the filter elements is possible, which prevents the build-up of a dense layer of solid particles and can therefore lead to increased filtrate flow. As a result of the completely sealed, sterile filter elements, the increased filter surface area and the resulting high filter efficiency and complete filtration with reduced residual volume shares, this system proves to be a cost-effective filtration device with high flow rates, minimized cleaning costs and short changeover times when changing products.