Flexible Filter Sock with Support Body for Air Filtration
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Solution Overview
Problem
Existing air filter systems are expensive, difficult to maintain, and have limited filter performance due to the need for complete replacement of filter cartridges and inefficient handling from the dirty air chamber.
Innovation Solution
A filter element with a flexible, bag-like filter sock and a dimensionally stable support body that allows for a larger effective filter surface area without increasing external dimensions, enabling easier maintenance and improved separation performance by forming waves and folds under air flow pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bag-like filter sock is used to cover a support basket tightly, then the filter element can be constructed simply, but the filter surface area is limited and filter performance is insufficient
Solution Approach 1:
The filter sock is designed with a loose fit around the support body, allowing it to form waves and folds in the radial direction. This dimensional transformation converts a simple cylindrical surface into a complex wavy surface, dramatically increasing the filter surface area without increasing the external dimensions of the filter element. The waves and folds create additional filtering surface in the radial dimension while maintaining the same overall filter element size.
2Stability of the object's composition
If filter cartridges are designed with rigid support structures, then structural stability is improved, but cost increases and maintenance becomes difficult
Solution Approach 1:
The filter element is segmented into two independent parts: a reusable support body and a replaceable filter sock. The support body provides structural stability and remains in the filter device, while the filter sock can be easily removed and replaced when worn. This segmentation allows the stable support structure to be retained while significantly easing maintenance, as only the filter sock needs replacement rather than the entire filter cartridge.
Solution Approach 2:
The filter sock is designed as a disposable or replaceable component that can be easily removed and replaced. Instead of designing the entire filter cartridge as a permanent assembly, the filter sock serves as a consumable part that is replaced when it reaches the end of its service life, reducing maintenance costs and complexity while maintaining structural stability through the reusable support body.
3Area of stationary object
If the filter sock is made dimensionally flexible to increase surface area, then filter performance improves, but the support structure becomes more complex
Solution Approach 1:
The filter sock is designed as a flexible, dimensionally unstable component that can be easily inserted over the support body and will naturally form waves and folds due to its flexibility. This flexible shell approach allows the filter medium to maximize its surface area without requiring a complex support structure, as the flexibility itself enables the wave formation that increases filtering surface while keeping the support body simple.
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 solution provides a more efficient and cost-effective filter performance with a 30% larger filter surface area, reducing maintenance intervals and mechanical wear, while allowing for longer filter sock use and improved energy efficiency by minimizing flow pressure.
Implementation Method 1
Filter element for cleaning an air stream that is charged with particles
Implementation Method 2
forming waves and folds under air flow pressure
Data Source
AI summary
The invention relates to a filter device (1) and a filter element (8) for cleaning an air stream that is charged with particles. The filter element (8) comprises a bag-type filter sock (17) consisting of an air-permeable, flexible material and a support body (21) in the interior of the bag-type filter sock (17). The first axial end of the bag-type filter sock (17) is closed and the second axial end has an air outlet that allows the cleaned air stream to exit the filter sock (17). An inner diameter or inner periphery of the filter sock (17) is greater in cross-sectional areas between the air outlet and its closed first end, in particular at least 10%, preferably between 20% and 40% greater than the greatest outer diameter or outer periphery of the support body (21), such that the filter sock (17) is dimensioned in relation to the support body (21) contained therein such that in the inactive state of the filter element (8) without air flow, said sock surrounds the support body (21) in a relatively loose manner and with lateral clearance. When air flows against the outer surface of the filter sock (17), folds or undulations are deliberately formed, at least in the jacket section of the filter sock (17), and the filter sock (17) thus lies comparatively closer to the support body (21).