Sinusoidal Filter Element with Angled Corrugated Separators
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Solution Overview
Problem
Existing filter systems for tooling machines face challenges in space constraints and efficiency when separating oil aerosols from exhaust air, requiring multiple filter mats for horizontal gas flow, which increases size, weight, and manufacturing costs.
Innovation Solution
A filter element with horizontal gas flow, featuring corrugated separators angled to optimize surface area usage and drainage, allowing for smaller dimensions, lower weight, and reduced manufacturing costs, with corrugated separators disposed at an angle to prevent overload and enhance fluid separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple filter mats are arranged in parallel for horizontal gas flow, then sufficient separation surface area is achieved, but device size, weight, and manufacturing costs increase
Solution Approach 1:
The patent transitions from a horizontal flow configuration requiring multiple parallel filter mats to a vertical flow configuration where a single folded filter element provides sufficient separation surface area. The filter medium is folded in a sinusoidal or zigzag pattern, creating multiple separation surfaces within a single element that processes gas vertically rather than horizontally.
Solution Approach 2:
The filter medium is segmented into multiple folds with separators spaced apart between adjacent folds. This segmentation creates multiple independent separation zones within a single filter element, allowing the gas to be processed through multiple surfaces sequentially as it moves vertically through the folded structure.
2Device complexity
If vertical flow configuration is used, then fewer filter elements are needed, but space requirement in extraction chamber increases
Solution Approach 1:
The filter element is nested within a compact housing structure that integrates with the extraction chamber. The folded filter medium is contained within a frame that fits into the available space, with the vertical flow path optimized to maximize separation efficiency within the constrained volume.
3Productivity
If corrugated separators are aligned vertically for vertical gas flow, then hollow channels are formed perpendicularly to horizontal axis, but insufficient separation efficiency for horizontal flow applications
Solution Approach 1:
Instead of aligning corrugations vertically for vertical flow, the patent inverts the approach by creating horizontal hollow channels through angled corrugations that extend across the depth of the folds. This allows the gas to flow horizontally through channels formed by the angled separators, improving separation efficiency for horizontal flow applications.
Solution Approach 2:
The corrugations are positioned at an angle offset from the vertical axis, creating asymmetric hollow channels that extend horizontally across the filter element. This asymmetric arrangement optimizes the flow path and separation efficiency for horizontal gas flow, differing from the symmetric vertical alignment used in traditional vertical flow designs.
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 angled corrugation design significantly improves fluid separation efficiency and reduces the need for multiple filter elements, achieving higher separation performance with lower costs and space requirements.
Implementation Method 1
a coalescing filter medium (40) which is folded in a sinusoidal or zigzagged manner forming multiple folds
Implementation Method 2
the separated fluid phase is drained out of the filter element by gravity
Implementation Method 3
the hollow channels, being formed by the corrugated separators, are arranged vertically... the gas mixture flowing through the filter element passes through these vertical channels
Data Source
AI summary
A filter element adapted to separate a dispersed fluid phase from a continuous phase of a gas mixture, comprising a coalescing filter medium being folded in a sinusoidal or zigzagged manner forming at least one fold, and at least one corrugated separator comprising sinusoidal or zigzag-shaped corrugations located in between adjacent longitudinal surfaces of the fold, wherein the heights of the corrugations extend perpendicularly to the length of the fold and wherein each corrugation comprises a corrugation depth axis extending across the depth of the fold.