Filter Element with Laid-in Yarns for Elongation Control
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Solution Overview
Problem
Filter elements used in large filtration machines, such as tower presses, are prone to elongation and abrasion, leading to premature failure and reduced working life due to their inherent stretch and susceptibility to abrasive particles.
Innovation Solution
A filter element design incorporating laid-in yarns that run parallel to the warp yarns, with a high ratio of laid-in yarns to warp yarns and using abrasion-resistant polyamide weft yarns, which reduces elongation and enhances abrasion resistance, and a sateen weave construction with polyamide yarns on both surfaces for improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If woven fabric filter elements are used in large filtration machines, then filtration function is achieved, but elongation occurs due to inherent stretch under tension
Solution Approach 1:
The filter element uses a composite construction combining woven fabric with non-woven layers. The non-woven layers contain laid-in yarns that run parallel to the warp yarns and do not interlace with weft yarns, creating a hybrid structure that reduces overall elongation while maintaining filtration capability.
Solution Approach 2:
The patent applies different material properties to different regions of the filter element. The non-woven layers with laid-in yarns are strategically positioned to provide elongation control in critical areas, while the woven fabric maintains filtration function. The laid-in yarns specifically target the elongation problem without compromising the filtration performance of the woven structure.
2Reliability
If filter elements are made from conventional materials, then basic filtration is achieved, but abrasion resistance is insufficient leading to premature failure
Solution Approach 1:
The filter element combines woven fabric with non-woven layers containing abrasion-resistant laid-in yarns. This composite structure provides enhanced durability by distributing mechanical stresses and protecting the woven fabric from abrasion, particularly from abrasive particles in the filtrate and contact with filtration apparatus surfaces.
Solution Approach 2:
The patent modifies the material composition and structural parameters of the filter element by incorporating non-woven layers with specific yarn arrangements. The laid-in yarns are positioned and configured to specifically address abrasion resistance, changing the surface properties and mechanical strength parameters of the filter element without fundamentally altering its filtration function.
3Area of stationary object
If filter elements are made longer to cover large filtration machines, then coverage is improved, but elongation and stretch increase significantly
Solution Approach 1:
The extended filter element uses a composite construction with non-woven layers containing parallel laid-in yarns that resist elongation. This allows the filter element to span large distances (up to 200m in vertical tower presses) while the composite structure minimizes cumulative stretch, maintaining tracking accuracy and preventing edge damage across the entire coverage area.
Solution Approach 2:
The non-woven layers with elongation-resistant laid-in yarns are distributed along the length of the extended filter element, providing localized reinforcement against stretch at critical points while maintaining overall coverage. This localized reinforcement strategy allows the filter element to achieve extended coverage without proportional increases in total elongation.
Data Source
AI summary
A filter element comprising two layers of weft (1) interlaced with warp (2). Additionally laid-in (3) yarns are provided in-between the two weft layers. The laid-in yarns (3) are not interlaced with the weft.