Duplex Polymer Melt Filter with Self-Cleaning Backflushing
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Solution Overview
Problem
The existing duplex filter devices for thermoplastics require high investment costs and labor-intensive cleaning processes due to the unused parallel filter unit, which also have environmental drawbacks.
Innovation Solution
Implementing a method where both filter chambers operate in parallel, allowing continuous filtering with simultaneous use of both filters, and initiating a backflushing mode when one filter reaches a predefined contamination level, using the filtered polymer melt to clean the other filter, thus reducing the overall filter surface and maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If both filter chambers are operated in parallel continuously, then productivity is improved and continuous operation is ensured, but device complexity increases due to requiring additional valves and control mechanisms for managing both filters simultaneously
Solution Approach 1:
The filter system is divided into two independent filter chambers (first and second) that can operate separately or simultaneously. Each chamber has its own inlet valve and drain valve, allowing independent control and operation. This segmentation enables continuous production by switching between chambers while keeping the overall system manageable through modular design.
Solution Approach 2:
The system dynamically switches between different operating modes (first filter chamber operation, second filter chamber operation, and parallel operation) based on contamination levels. The control mechanism adapts the operational state of valves and pump based on real-time filter conditions, optimizing productivity while managing complexity through dynamic rather than static operation.
2Device complexity
If the filter surface area is reduced by using only one filter chamber at a time, then device complexity and investment costs decrease, but productivity decreases due to alternating operation requirements
Solution Approach 1:
Both filter chambers are designed with identical structures and capabilities, allowing either chamber to perform the filtration function. This universality enables the system to maintain high productivity by having both filters ready for operation while reducing complexity through standardized design elements that can be used interchangeably.
Solution Approach 2:
The system maintains continuous filtration capability by ensuring that at least one filter chamber is always operational. When one chamber becomes contaminated, the other chamber continues processing, and the contaminated chamber is cleaned offline. This continuity approach maximizes productivity while allowing simplified operation of individual chambers when needed.
3Reliability
If traditional cleaning methods (pyrolysis, chemical solutions, ultrasonic baths) are used, then cleaning effectiveness is improved, but harmful factors increase due to environmental impact and energy consumption
Solution Approach 1:
The system uses the filtered polymer melt itself as the cleaning medium for the filter chambers. The clean polymer melt from one chamber is redirected to clean the other chamber, eliminating the need for external cleaning agents. This self-service approach maintains cleaning effectiveness while completely eliminating environmental harm from chemical solutions and reducing energy consumption compared to pyrolysis and ultrasonic methods.
Solution Approach 2:
Instead of discarding the filtered polymer melt after use, the system recovers and reuses it as a cleaning medium. The melt that has already been filtered once is redirected to clean the filter chambers, transforming a waste product into a valuable cleaning resource. This recovering approach eliminates harmful environmental factors while maintaining effective cleaning.
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
This approach reduces the size and cost of the filter device, ensures continuous operation, and extends the service life by simplifying the cleaning process, using the filtered polymer melt to clean filters, thereby minimizing environmental impact and labor.
Implementation Method 1
The backflushing mode of operation is initiated when both large-area filters have reached a predefined degree of contamination meaning that it is necessary to clean the first large-area filter using a backflushing mode of operation
Implementation Method 2
The side walls of the filter candles constitute the filter. More specifically, the side walls can be corrugated, or shaped in any other way, in the circumferential direction so as to increase the filter surface
Data Source
AI summary
A method operates a filter device for polymer melt to be filtered. The filter device incorporates at least one first large-area filter in a first filter chamber and a second large-area filter in a second filter chamber; a first valve in a first inlet to the first filter chamber and a second valve in a second inlet to the second filter chamber to control the polymer melt to be filtered; a first drain valve in a first drain for the filtered polymer melt from the first filter chamber and a second drain valve in a second drain for the filtered polymer melt from the second filter chamber. The polymer melt to be filtered is conveyed under pressure through the filter device. The first inlet and the second inlet are connected to a common inlet and the first drain and the second drain are connected to a common drain. Polymer melt to be filtered is simultaneously fed to the first and second large-area filters in the filter direction. Parallel filtering is continuously performed via the first and second large-area filters. A backflushing operation for filtering via only one large-area filter is started when the large-area filter reaches a predefined degree of contamination at which the first large-area filter is cleaned.