Filter Fabric With Offset Threads For Clogging Resistance
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Solution Overview
Problem
Existing filter fabrics face challenges in varying flow rate and filter fineness without clogging, as the warp wires wrapping around weft wires create solid contact, restricting particle entry and exit.
Innovation Solution
The filter fabric design features crimped threads running parallel to each other, guided alternately around thicker straight threads, creating openings for particle entry and exit, with the straight threads' thickness enhancing flow rate and filter fineness by creating a suction effect similar to a venturi nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If warp wires wrap around weft wires by 360° to provide multiple pores, then filtration fineness is improved, but the fabric becomes clogged because there are no openings between the twisted warp wires
Solution Approach 1:
The fabric structure is segmented into two functional components: crimped threads that provide filtration pores and straight threads that maintain flow channels. This segmentation allows the fabric to simultaneously achieve fine filtration and high flow rate by separating the filtration function from the flow function.
Solution Approach 2:
Different regions of the fabric have different thread configurations tailored to specific functions. The crimped threads create local filtration zones with small openings for particle capture, while the straight threads create local flow zones with larger openings for maintaining high flow rate. This local differentiation resolves the contradiction between filtration fineness and flow rate.
2Manufacturing precision
If crimped threads are used to define filter fineness, then filtration precision is improved, but flow rate decreases due to restricted particle entry and exit
Solution Approach 1:
The fabric is segmented into crimped threads for filtration and straight threads for flow, allowing each component to optimize its function without compromising the other.
Solution Approach 2:
The straight threads add a dimensional element to the fabric structure, creating three-dimensional flow channels that bypass the two-dimensional crimped thread network. This dimensional addition provides alternative pathways for fluid flow, increasing flow rate while maintaining filtration precision.
3Productivity
If straight threads are made thicker to increase flow rate, then flow rate is improved, but fabric complexity increases
Solution Approach 1:
The fabric merges two simple thread types (crimped and straight) into a unified woven structure. Each thread type has a simple geometry, but their combination creates the complex functionality of simultaneous fine filtration and high flow rate. This merging approach achieves complexity of function without complexity of individual components.
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
This design allows for adjustable flow rate and filter fineness, preventing clogging, facilitating easy flushing of particles, and enabling efficient filtration of small particles across various media, including gases and liquids, with improved air permeability and porosity.
Implementation Method 1
the thickness of the straight thread, the exit from the fabric is greater than the entry between the crimped threads into the weave. As a result, the widening cross-section causes a suction effect, which, like a venturi nozzle, has a positive effect on the flow.
Data Source
Figure 1~2
AI summary
The invention relates to a filter fabric with offset threads extending parallel to each other and which are guided alternately about parallel straight threads extending perpendicular thereto, in order to form woven fabric.