Pre-tensioned Stainless Steel Filter Cloth on Composite Grillwork Frame
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional stainless steel filter cloths in disk filters suffer from fatigue and premature breakage due to hydraulic loads, requiring complex and costly frames and welding processes, which increase costs and reduce the economic benefits of improved permeability and cleaning efficiency.
Innovation Solution
A filtering panel with a stainless steel cloth pre-tensioned in both warp and weft directions and attached to a frame made of polypropylene loaded with glass fibers, featuring an integral grillwork that divides the inner area into fields, minimizing deflection and fatigue while maintaining high filtration capacity and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stainless steel filter cloths are used with high permeability and cleaning efficiency, then filtration performance is improved, but the cloths suffer from fatigue and premature breakage due to hydraulic loads
Solution Approach 1:
The frame is divided into a peripheral portion and an inner grillwork structure. The grillwork creates multiple small fields that collectively support the filter cloth, distributing the hydraulic load across numerous support points rather than relying on a continuous rigid frame. This segmentation reduces the deflection and stress on any single area of the stainless steel cloth, preventing fatigue while maintaining high permeability.
Solution Approach 2:
The invention uses a composite frame structure combining plastic material (polypropylene) with metal reinforcement (stainless steel grillwork). This composite approach provides the necessary rigidity to support the stainless steel filter cloth while avoiding the complete rigidity of a full metal frame, thereby reducing the hydraulic load deflection that causes cloth fatigue. The plastic material provides corrosion resistance and structural stability.
2Reliability
If rigid frames are used to minimize deflection of stainless steel cloths, then cloth lifetime is extended, but device complexity and manufacturing costs increase
Solution Approach 1:
Instead of a single rigid frame structure, the support system is segmented into a peripheral portion and an inner grillwork with multiple fields. This segmentation achieves the necessary structural rigidity to minimize cloth deflection while keeping each individual component simpler and easier to manufacture. The modular grillwork structure reduces overall device complexity compared to a monolithic rigid frame.
Solution Approach 2:
The frame structure applies rigidity locally where needed through the grillwork fields that directly support the filter cloth, rather than making the entire frame uniformly rigid. The peripheral portion provides boundary support while the inner grillwork provides distributed support across the filtering area. This localized approach to rigidity reduces manufacturing complexity and material costs while effectively extending cloth lifetime.
3Stability of the object's composition
If stainless steel frames are used to support metal cloths, then cloth stability is improved, but manufacturing costs and attachment complexity increase
Solution Approach 1:
The frame uses a composite construction with plastic material as the base and integrated metal grillwork reinforcement. This composite structure provides the stability needed to support stainless steel filter cloths while being more cost-effective than a fully metal frame. The plastic material is easier and less costly to manufacture, and the integrated grillwork provides the necessary structural stability without requiring separate metal frame components.
Solution Approach 2:
The peripheral portion and inner grillwork are merged into a single integrated frame structure. This merging simplifies manufacturing by eliminating the need for separate metal frame components and complex assembly processes. The integrated structure maintains cloth stability while reducing overall manufacturing cost and attachment complexity compared to traditional stainless steel frame systems.
4Reliability
If filter cloth is pre-tensioned to minimize deflection under hydraulic load, then fatigue is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The grillwork divides the inner area into multiple small fields, each providing localized support to the filter cloth. This segmentation reduces the span between support points, thereby reducing deflection under hydraulic load. As a result, the cloth experiences less stress and fatigue, and the tensioning process requires less precision because the structural support does much of the work in minimizing deflection.
Solution Approach 2:
The frame structure is designed with pre-integrated grillwork fields that provide preliminary support to the filter cloth before the cloth is even installed. This preliminary structural support reduces the initial deflection and stress on the cloth, making the subsequent tensioning process more forgiving and less demanding of manufacturing precision while still achieving fatigue resistance.
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 significantly extends the lifetime of metal filter cloths, reduces manufacturing costs, and allows for easier and less costly attachment, while maintaining high filtration efficiency and compatibility with existing polyester cloth frames.
Implementation Method 1
a frame (110) consisting of a plastic material loaded with fibres of glass or carbon
Implementation Method 2
the filter cloth is pre-tensioned in both warp and weft directions at least 20% of the yield stress of the cloth
Implementation Method 3
they are affected by the resulting phenomenon of fatigue, which leads them to premature breakage
Implementation Method 4
The filtration takes place from the inside out, that is to say the filtering takes place from the inside of the filter member and out through the filter cloth
Data Source
AI summary
The present invention relates to a filtering panel (100) for a disk filter and a disk filter for water purification, comprising a metal filter cloth (16, 116) such as a stainless steel filter cloth, pre-tensioned in both warp and weft directions and fastened to a frame (10, 110) comprising a peripheral portion (11, 111), which is integral with an inner grillwork (12) and which divides the inner area of the peripheral portion (11, 111) into fields (15, 115). The frame (10, 110) comprises a plastic material reinforced with glass fibers or carbon fibres such as polypropylene loaded with fibreglass in an amount of at least 20 weight percent. Each field of the grillwork (12, 112) has an area not exceeding 10% of the inner area of the peripheral portion (11, 111). The pre-tensioning of the filter cloth (16, 116) in both directions is from at least 20% of the yield stress of the cloth (16, 116). Further the present invention relates to a disk filter comprising said filtering panels (100) and method of making said filtering panel (100).