Filter Pleat Tip Geometry Optimization for Airflow and Dust Capacity

Solution Overview

Problem

Conventional filter elements for rotary machines, such as gas turbines, face challenges in balancing airflow efficiency and mechanical resistance due to fixed pleat shapes and sizes, which affect dust holding capacity and pressure drop across the filter.

Innovation Solution

A filter element design featuring multiple sets of pleats with varying tip radii and spacings, optimizing airflow by combining sharp and rounded pleat tips to enhance dust holding capacity and reduce pressure drop, while maintaining structural integrity across different operational environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fixed pleat shapes and sizes are used in filter elements, then manufacturing is simplified, but airflow efficiency and dust holding capacity are compromised

Engineering Contradiction:

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The filter element is divided into multiple sets of pleats (first set, second set, etc.) with different geometries. Each set can have different tip radii, spacings, and orientations, allowing the filter to optimize airflow and dust holding capacity through segmented functional zones while maintaining manufacturability through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the filter element have different pleat characteristics tailored to local requirements. For example, certain areas may have sharper pleat tips for better dust holding capacity while other areas have rounded tips for lower pressure drop, creating local optimization throughout the filter structure

Inventive Principle:

Principle #3Local quality

2Strength

If pleat tip radius is increased (rounder tips), then structural integrity is improved, but dust holding capacity decreases

Engineering Contradiction:

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The filter element segments pleats into different groups with different tip radii. Some pleat sets have larger tip radii for structural strength while other sets have smaller tip radii for enhanced dust holding capacity, resolving the contradiction through spatial distribution of different geometric properties

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filter design employs asymmetric pleat configurations where different pleat sets have deliberately different tip radii rather than uniform symmetry. This asymmetry allows optimization of both structural integrity and dust holding capacity in different regions of the filter element

Inventive Principle:

Principle #4Asymmetry

3Area of moving object

If pleat spacing is decreased, then filter surface area is increased, but pressure drop increases

Engineering Contradiction:

Core Design Contradiction:

Area of moving objectVSStress or pressure

Solution Approach 1:

The filter element is divided into multiple pleat sets with different spacings. Certain sets have tighter spacing to maximize surface area for dust capture, while other sets have wider spacing to reduce pressure drop, allowing the system to achieve both high surface area and low resistance through segmented design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the filter have locally optimized pleat spacings based on functional requirements. Areas with higher dust loading may have tighter spacing for greater surface area, while inlet or outlet regions may have wider spacing to minimize pressure drop, creating local quality variations throughout the filter

Inventive Principle:

Principle #3Local quality

4Quantity of substance

If pleat tip radius is decreased (sharper tips), then dust holding capacity is improved, but structural integrity worsens

Engineering Contradiction:

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The filter segments pleats into multiple sets where some have sharp tips for dust holding capacity while others have rounded tips for structural strength. This segmentation allows the filter to exhibit both sharp and rounded tip characteristics in different locations, resolving the contradiction between dust holding capacity and structural integrity

Inventive Principle:

Principle #1Segmentation

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 filter element design improves airflow efficiency and dust holding capacity by adjusting pleat geometry, optimizing performance across a range of environments without substantial increases in size or weight, thereby enhancing the overall efficiency of rotary machines.

Implementation Method 1

The media within the filter elements may be pleated to increase the filter surface area, without substantially increasing the overall size and weight of the filter elements

Methodology Applied

Scientific EffectPleating: Corrugation

Data Source

PatentEP2617962B1Filter assembly including pleat tip shapes

Publication Date: 2019.09.25

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AI summary

Solutions for efficiently filtering air for a machine are disclosed. In one embodiment, a filter element (100) for a filter assembly of a rotary machine is provided. The filter element includes: a first set of pleats (110), each pleat including a first tip radius and a first spacing; and a second set of pleats (120), each pleat including a second tip radius and a second spacing, wherein the first and second set of pleats (110, 120) are positioned upon a continuous filter media.