Foldable Support Drainage Material for Filter Flow Distribution
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Solution Overview
Problem
Existing support and drainage elements in filtration applications are inadequate in providing efficient support and drainage, leading to issues such as uneven fluid distribution, increased pressure drop, and potential damage to filter media.
Innovation Solution
The use of foldable support and drainage materials with tapered sections and apertures, allowing for adjustable thickness and improved fluid flow channels, which are placed upstream and downstream of pleated filters to provide uniform support and drainage while reducing edgewise flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional constant thickness support and drainage materials are used, then the structure is simple and easy to manufacture, but the fluid flow distribution is uneven and pressure drop increases
Solution Approach 1:
The support and drainage material uses variable thickness design where different sections have different thicknesses to match local flow rates. Thicker sections are placed where higher flow rates occur and thinner sections where lower flow rates occur, optimizing fluid distribution throughout the filter element.
Solution Approach 2:
The material transitions from static constant thickness to dynamic variable thickness that adapts to local flow conditions. The tapered and stepped thickness variations allow the material to respond to varying fluid pressures and flow rates at different locations within the filter.
2Ease of operation
If foldable elements with apertures are used, then fluid flow distribution improves, but manufacturing complexity increases
Solution Approach 1:
The material is divided into multiple foldable sections with apertures that can be manufactured separately and then assembled. This segmentation allows for easier manufacturing of complex variable thickness structures by creating modular components that are simpler to produce individually.
Solution Approach 2:
The foldable sections with apertures are designed to nest within each other when folded, creating a compact variable thickness structure. The apertures in one section accommodate the bulk of adjacent sections, allowing the material to achieve complex three-dimensional thickness variations from simpler two-dimensional manufacturing.
3Productivity
If tapered sections are used to match local flow rates, then filtration efficiency improves, but structural complexity increases
Solution Approach 1:
The material employs tapered sections with gradual curvature transitions rather than abrupt angle changes. This curved geometry allows for smoother fluid flow paths and reduces structural complexity compared to sharp angular transitions, while still achieving the variable thickness needed to match local flow rates.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 2C~2E
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 about 25% to 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/or 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 about 25% to 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/or a part of the second section bulk thickness fits in the at least one aperture of the at least one first section. Filter including this material and methods of use.