Foldable Filter Support Material with Nested Apertures
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Solution Overview
Problem
Existing support and drainage elements in filtration systems are inadequate in providing effective support and drainage while minimizing edgewise flow resistance and preventing filter media damage, especially when used with pleated filters.
Innovation Solution
A foldable support and drainage material system comprising mesh or non-woven fabric sections with specific aperture configurations that allow fluid flow, enabling the material to be folded and fitted together to reduce thickness and prevent nesting, while maintaining fluid flow and supporting pleated filters effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional support and drainage elements are used with pleated filters, then they provide basic support and drainage, but they cause increased edgewise flow resistance and potential filter media damage
Solution Approach 1:
The support and drainage element is designed with nested sections where one section is inserted into an aperture of another section, creating a compact configuration that prevents nesting issues while maintaining support and drainage functionality, thereby reducing edgewise flow resistance and preventing filter media damage
Solution Approach 2:
The support and drainage element is divided into multiple sections (first section, second section, additional first section, additional second section) that can be folded and nested relative to each other, allowing the element to provide effective support and drainage while minimizing edgewise flow resistance through the segmented, collapsible structure
2Strength
If support and drainage elements are made thicker to provide better support, then support capability improves, but the elements take up more space and increase edgewise flow resistance
Solution Approach 1:
The element is designed with nested sections where thicker sections provide support capability while being able to collapse into each other, maintaining strength when needed but minimizing volume when collapsed, thereby reducing edgewise flow resistance and space occupation
Solution Approach 2:
The support and drainage element transitions from a rigid, fixed-thickness structure to a dynamic, collapsible structure that can change its effective thickness based on operational needs, providing support when necessary while minimizing space occupation during storage or transport
3Volume of moving object
If foldable support and drainage elements are designed with apertures for nesting, then space efficiency improves, but fluid flow capability may be compromised
Solution Approach 1:
The element is designed with different aperture configurations in different sections (first section, second section, additional first section, additional second section), where each section has apertures optimized for its specific function, allowing nesting capability in some areas while maintaining fluid flow capability in others
Solution Approach 2:
The element is segmented into multiple sections with apertures positioned and sized differently in each section, allowing the nested configuration to be achieved while maintaining adequate fluid flow paths through the segmented structure, as each section contributes to both nesting and flow functionality
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C~2D
AI summary
A support and drainage material comprising: a foldable element allowing fluid flow through, the element comprising: at least one first section comprising a mesh or a non-woven fabric having a first end and a second end, a first side and a second side, a first major surface and a second major surface, and a first section bulk between the first major surface and the second major surface, the first section bulk having a thickness extending from the first end to a portion of the second end; wherein the at least one first section further comprises at least one first section aperture extending a length of at least about 75% a distance between the first end and the second end, and extending a length of about 2% to about 100% a distance between the first side and the second side; and, at least one second section comprising a mesh or a non-woven fabric having a first end and a second end, a first side and a second side, a first major surface and a second major surface, and a second section bulk between the first major surface and the second major surface, the second section bulk having a thickness extending from the first end to a portion of the second end; wherein the at least one second section further comprises at least one second section aperture extending a length of at least about 75% a distance between the first end and the second end, and extending a length of about 2% to about 100% a distance between the first side and the second side;wherein, when the foldable element is folded, a part of the first section bulk thickness fits in the at least one aperture of the at least one second section, and a part of the second section bulk thickness fits in the at least one aperture of the at least one first section. Filter including the support and drainage material, and methods of use are also disclosed.