Extruded Underdrain Assembly for Uniform Backwash Distribution
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Solution Overview
Problem
Existing underdrain assemblies for water filtration systems are complex, heavy, and consist of many parts, leading to high production, installation, and maintenance costs, as well as inefficiencies in wash water distribution during backwashing.
Innovation Solution
An extruded underdrain apparatus made from a formable material, such as metals or polymers, is manufactured as a unitary part with integrated orifices, allowing for longer sections and reduced components, which minimizes end-to-end connections and assembly costs, and can be interconnected to cover the filter basin floor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional underdrain assemblies are constructed with multiple discrete components and support media layers, then the filter media can be supported and washed water distributed, but the device becomes complex, heavy, and difficult to install with high production and maintenance costs
Solution Approach 1:
The patent combines multiple discrete underdrain components into a single integrated underdrain assembly that includes the underdrain body, support media layers, and filter media all in one unit. This merging eliminates the complexity of assembling multiple separate parts while maintaining the functional integrity of wash water distribution and filter media support throughout the filtration system.
2Ease of manufacture
If traditional underdrain assemblies use multiple discrete components requiring end-to-end connections, then coverage of the filter basin floor can be achieved, but installation becomes time-consuming and leakage risks increase
Solution Approach 1:
The integrated underdrain assembly combines the entire underdrain structure into one continuous component that can be manufactured as a single piece. This eliminates the need for multiple end-to-end connections during installation, reducing both installation time and the risk of leakage at connection points while still providing complete coverage of the filter basin floor.
3Strength
If heavy traditional underdrain assemblies are used to provide structural support, then the filter media bed can be supported, but shipping and installation difficulties increase
Solution Approach 1:
The patent utilizes composite material construction for the underdrain assembly, combining materials that provide both the necessary structural strength to support the filter media bed and reduced weight compared to traditional heavy-duty constructions. This composite approach maintains structural integrity while improving ease of shipping and installation.
4Reliability
If support media layers are used to prevent filter media from entering underdrain apertures, then filter media containment is achieved, but the device becomes heavier and more complex
Solution Approach 1:
The integrated underdrain assembly merges the support media layers directly into the underdrain structure as built-in components rather than separate layers requiring assembly. This integration maintains effective filter media containment at the apertures while reducing the overall complexity and number of discrete components that would otherwise be required.
Data Source
AI summary
An underdrain apparatus and a method for manufacturing such apparatus are provided. The underdrain apparatus can be extruded in long sections as a unitary part. The underdrain apparatus may be extruded in various sizes, shapes, and materials. Further, the underdrain apparatus may include a passageway for transporting water to and from the filter media and/or air to the filter media. In some embodiments, apertures are formed in the underdrain apparatus during an extrusion process to provide a path between the passageway and the filter media.