Foldable Support Drainage Material for Filter Uniform Flow
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Solution Overview
Problem
Existing support and drainage elements in filtration applications lack efficiency in providing both support and drainage, leading to issues such as nesting of mesh strands and uneven fluid distribution, which results in increased pressure drop and potential damage to filter media.
Innovation Solution
The development of a foldable support and drainage material system with flexible hinges and apertures, allowing sections to interlock and provide parallel flow channels, which reduces edgewise flow resistance and allows for uniform fluid distribution while maintaining support and reducing the need for multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional mesh support and drainage elements are used, then support structure is provided, but nesting of mesh strands occurs and fluid distribution becomes uneven
Solution Approach 1:
The support and drainage element is divided into multiple pleated sections that can be independently formed and then interlocked. Each pleat acts as a separate structural unit with defined flow channels, preventing the nesting issue that occurs with continuous mesh structures while maintaining overall structural stability.
Solution Approach 2:
The invention uses interlocking pleated sections where one pleat fits into another in a controlled manner. This controlled nesting through interlocking flanges and channels prevents unwanted mesh strand nesting while establishing uniform fluid distribution paths through the defined geometry of the pleated structure.
2Reliability
If multiple layers of support and drainage material are used, then support and drainage capability is improved, but device complexity and waste increase
Solution Approach 1:
The invention combines both support and drainage functions into a single integrated pleated structure. The pleated geometry simultaneously provides mechanical support to the filter medium and creates defined flow channels for drainage, eliminating the need for separate support layers and drainage layers that would increase complexity and material usage.
Solution Approach 2:
The pleated support and drainage element serves multiple functions: it provides structural support to the filter medium, creates uniform fluid distribution, establishes defined drainage pathways, and prevents media damage. This multi-functionality in a single component reduces the number of layers needed compared to traditional multi-layer constructions.
3Strength
If traditional support elements are used, then filter media support is provided, but pressure drop increases and media damage may occur
Solution Approach 1:
The pleated structure provides localized support exactly where needed through its geometric configuration. The interlocking pleats create specific contact points and distributed support zones that provide necessary mechanical strength to the filter medium while maintaining open flow channels, avoiding the high pressure drop associated with dense mesh structures.
Solution Approach 2:
The invention transitions from a two-dimensional mesh structure to a three-dimensional pleated structure with defined depth and volume. This dimensional change creates internal flow channels within the pleats themselves, providing support strength through the three-dimensional geometry while maintaining low resistance fluid pathways, thereby reducing pressure drop.
Data Source
Figure 1A~1C
Figure 2A~3C
Figure 4A~4C
AI summary
A support and drainage material comprising a foldable element comprising: at least one first section 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 plurality of parallel flow channels extending from the first end to the second end, the flow channels comprising side walls arranged in parallel and projecting upwardly from, and perpendicular to, the first major surface, the side walls having top walls; and, at least one second section 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 plurality of parallel flow channels extending from the first end to the second end, the flow channels comprising side walls arranged in parallel and projecting upwardly from, and perpendicular to, the first major surface, the side walls having top walls; wherein the first section is connected to the second section by a flexible hinge; 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/or 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 portion of the first section fits in the at least one aperture of the at least one second section, and/or a portion of the second section fits in the at least one aperture of the at least one first section, providing parallel flow channels. Filter including the materials, and method of use are also disclosed.