Cleanable filter medium
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Solution Overview
Problem
Existing filters face issues with clogging over time, leading to increased pressure drops and energy consumption, necessitating frequent replacement or cleaning, which is time-consuming and expensive.
Innovation Solution
A cleanable filter medium comprising a non-woven textile layer of synthetic organic polymer fibers with an embossed pattern, consolidated using thermoplastic binders and mechanical means, maintaining filtration efficiency and dust holding capacity through multiple cleaning cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media is used to remove solids from liquids and/or gaseous fluids, then filtration efficiency is improved, but clogging occurs with service time leading to increased pressure drop and energy consumption
Solution Approach 1:
The patent applies reverse flow cleaning by inverting the flow direction of the filtration fluid to remove accumulated solids from the filter media. This inversion mechanism allows the filter to be cleaned in-situ without replacement, resolving the contradiction between maintaining filtration efficiency and avoiding energy loss from frequent replacements or cleanings.
Solution Approach 2:
The patent utilizes phase transition of the filtration fluid (e.g., temperature changes causing condensation or evaporation) to enhance the cleaning effect during reverse flow. By changing physical parameters of the cleaning fluid, the filter media can be effectively cleaned of accumulated solids, maintaining low pressure drop and energy consumption over extended service life.
2Reliability
If filter media is replaced or cleaned frequently to maintain filtration efficiency, then filtration performance is maintained, but time and cost increase
Solution Approach 1:
The filter system performs self-cleaning through automated reverse flow mechanisms without requiring manual intervention or system shutdown. The filtration fluid itself is used to clean the filter media, making the system self-maintaining and eliminating time losses associated with frequent manual replacements or cleanings while sustaining filtration efficiency.
Solution Approach 2:
The patent implements periodic reverse flow cleaning cycles to prevent clogging before it significantly impacts filtration efficiency. By applying cleaning pulses at optimal intervals, the filter maintains consistent performance over extended periods, reducing both maintenance time and operational disruptions compared to continuous or frequent manual maintenance.
3Reliability
If conventional filter media is used, then initial filtration efficiency is achieved, but service life is limited due to clogging and pressure drop
Solution Approach 1:
The patent ensures continuous filtration efficiency by implementing automated reverse flow cleaning that prevents clogging accumulation. This continuous maintenance of filter permeability extends the service life of the filter media significantly, allowing it to operate at optimal efficiency for much longer periods without replacement, thus resolving the contradiction between initial efficiency and sustained service life.
Solution Approach 2:
The system performs preliminary cleaning actions during operation through periodic reverse flow pulses that remove solids before they cause significant clogging. This preventive maintenance approach extends the functional life of the filter media while maintaining consistent filtration efficiency, avoiding the need for frequent replacements.
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 filter medium exhibits improved filtration efficiency, increased dust holding capacity, and reduced pressure drop even after numerous cleaning cycles, extending its service life and reducing maintenance costs.
Implementation Method 1
Filter media are described in EP-A-0878226, EP-A-1134013, DE-A-2000139245 and EP-A-0980700, for example. Filters are adapted to achieve a satisfactory filtration efficiency and service life depending on the field of application. Removing solids from liquids and/or gaseous fluids is a most common field of filtration.
Implementation Method 2
a3) the nonwoven being consolidated by means of thermoplastic binders and/or mechanical means
Implementation Method 3
a3) the nonwoven being consolidated by means of thermoplastic binders and/or mechanical means
Data Source
AI summary
The present invention relates to a cleanable 3D filter medium, a method for manufacturing said filter and the use of the filter.The filter medium according to the present invention comprises at least one textile layer being a non-woven of synthetic, organic polymer fibers. The nonwoven having an embossed pattern in which the nonwoven having at the non-embossed area a thickness D and at the embossed area a thickness d and the ratio d/D is the compression factor CF, said compression factor CF being in the range 0.2≤FC≤0.5.The filter medium according to the present invention can be cleaned and are used in filter systems for air/gas and liquid filtration, particularly in the motor vehicle industry, in air conditioning systems, passenger compartment filters, pollen filters, clean room filters, domestic filters, and as oil filters and hydraulic filters, thus removing solids from air/gas and liquids.