Integrated Filter Disk Segments for Higher Flow and Lower Residence Time
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Solution Overview
Problem
Commercially available filter disk segments consist of multiple separately produced components, which are inefficient and require improvements for enhanced performance and manufacturing ease.
Innovation Solution
A filter disk segment design comprising a central hub supporting two porous components with raised fluid flow channels or ribs, and a drainage component, allowing for integrated construction and increased effective filter area without excess residence time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separately produced components are used, then manufacturing flexibility is maintained, but device complexity and manufacturing efficiency deteriorate
Solution Approach 1:
The patent combines multiple separately produced components (spacer, filter media, slotted support) into a single integrated filter disk segment. The filter media is formed with integrated flow channels and support structures, eliminating the need for separate components and reducing assembly steps while maintaining manufacturing flexibility through modular disk segment design.
Solution Approach 2:
The integrated filter disk segment performs multiple functions simultaneously: the filter media provides filtration, the integrated flow channels provide fluid distribution and collection, and the support structures provide mechanical strength. This multi-functionality reduces the number of separate components needed while maintaining ease of manufacture through a unified design.
2Reliability
If filter area is increased, then filtering efficiency is improved, but residence time increases
Solution Approach 1:
The patent transitions from a flat filter surface to a three-dimensional pleated bellows structure. The pleats create multiple flow paths and increase the effective filter area without proportionally increasing the residence time, as fluid flows through the pleats in a controlled manner that maintains optimal contact time. This dimensional transformation allows higher filtering efficiency while managing residence time.
Solution Approach 2:
The filter media is segmented into pleats or folds, creating multiple parallel flow paths. This segmentation increases the effective filter area by creating numerous smaller flow channels rather than one large open space, allowing fluid to be distributed across more filtration surface while maintaining shorter residence times through parallel processing of the fluid stream.
3Productivity
If more segments fit in housing, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The filter system is divided into modular disk segments that can be independently manufactured and then assembled into the housing. Each segment is a self-contained unit with standardized interfaces, allowing multiple segments to fit in a given housing volume. The modular design simplifies assembly precision requirements compared to manufacturing a single large filter, as each segment can be produced with standard tolerances and then precisely assembled.
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 design provides higher flow rates, reduced residence time, and allows more segments to fit in a given housing, while maintaining desirable filtering efficiency and reducing manufacturing complexity.
Implementation Method 1
a first porous component including a first end by the central hub opening, and a second end distal to the first end, the first porous component having an upper surface including at least two raised fluid flow channels having porous walls
Implementation Method 2
the drainage component allowing fluid flow therethrough arranged between, and in fluid communication with, the first porous component and the second porous component
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Filter disk segments, methods of use, and filter devices including the filter disk segments are disclosed.