Filter Insert Layout for Uniform Paint Particle Separation
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Solution Overview
Problem
Existing filter modules for air purification in spray booths suffer from uneven particle adhesion due to abrupt airflow redirection, leading to reduced efficiency and lifespan, and require time-consuming replacement of individual cleaning elements when disassembled.
Innovation Solution
A filter module design with air-permeable transverse walls and open sections that allow continuous, laminar airflow without baffles, enabling balanced particle adhesion and sequential saturation of all walls, allowing for a single replaceable filter insert with extended service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If baffles with openings are used to create meandering airflow pattern, then particle separation is achieved, but particle adhesion becomes highly uneven and first chamber captures majority of particles
Solution Approach 1:
The patent removes the baffles (partition walls with openings) from the filter module design. Instead of using baffles to create meandering airflow, the invention uses a single continuous filter medium that extends throughout the module, allowing airflow to pass through uniformly without abrupt redirections that cause uneven particle adhesion.
Solution Approach 2:
The patent employs a filter medium with controlled porosity that allows uniform airflow distribution. The filter medium consists of a continuous structure with pores that enable air to pass through while capturing particles uniformly across the entire surface, eliminating the need for baffles with openings that cause localized particle accumulation.
2Reliability
If multiple cleaning structures are arranged one behind another within base body, then particle separation is improved, but replacement of individual elements becomes extremely time-consuming
Solution Approach 1:
The patent divides the filter module into a reusable base body and a replaceable filter insert. The filter insert containing the filter medium can be easily removed and replaced as a single unit, while the base body remains in place. This segmentation allows quick maintenance without disassembling the entire module or accessing individual cleaning elements.
Solution Approach 2:
The base body is designed to be reusable and accommodate the replaceable filter insert. This universal design allows the same base body to work with multiple filter inserts over time, reducing waste and simplifying maintenance. The modular approach enables the system to maintain its particle separation performance while significantly reducing replacement time.
3Reliability
If airtight material is used for impact walls, then particles can adhere to surface, but airflow is deflected and energy consumption increases
Solution Approach 1:
The patent replaces airtight impact walls with a porous filter medium that allows air to pass through while capturing particles. The filter medium's porous structure enables uniform airflow distribution without abrupt deflections, reducing energy consumption while maintaining particle separation efficiency. Air flows through the pores of the filter medium rather than being redirected around airtight barriers.
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
Improves separation efficiency by over 100% and reduces energy consumption by at least 30% compared to prior art, with the ability to operate continuously without redirection and minimize energy requirements.
Implementation Method 1
a filter element (9), in particular a nonwoven fabric, which is at least partially air-permeable, wherein an open section (10) is formed in or next to the filter element (9), so that the airflow (4) from the inlet side (3) towards the outlet side (5) can flow on the one hand through the filter element (9) and on the other hand through the open section (10)
Implementation Method 2
enabling balanced particle adhesion and sequential saturation of all walls, allowing for a single replaceable filter insert with extended service life
Data Source
Figure 1(a)~3(b)
Figure 4(a)~5
Figure 6~8
AI summary
The present invention relates to a filter module for separating particles from contaminated air, in particular for separating paint particles from an airflow, comprising a receiving element having an inlet side for the entry of an airflow to be cleaned and an outlet side for the exit of the cleaned airflow, wherein the inlet side and the outlet side are arranged opposite each other on the receiving element, at least one filter insert which is received in the receiving element, wherein the filter insert has at least one transverse wall, and the transverse wall is formed from a filter element that is at least partially air-permeable, wherein an open partial area is formed in or next to the filter element, so that the airflow from the inlet side towards the outlet side can flow firstly through the filter element and secondly through the open partial area.