Pleated Fuel Water Separator Embossing for Low Pressure Drop
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Solution Overview
Problem
Existing coalescing filtration systems for hydrocarbon fuels suffer from high pressure drop across the filter element due to the filtration media, leading to a high concentration of water at the bottom of the filter element before collection, necessitating a need for improved filtration elements with reduced pressure differential while maintaining effective water coalescence.
Innovation Solution
The development of pleated filter elements with pleat flanks featuring structural embossments of varying geometries, angles, and orientations, along with enhanced surface roughness, to enhance water coalescence and reduce pressure drop by angling embossment axes to facilitate gravitational water flow and block re-introduction of coalesced droplets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter media is used for water coalescence, then water separation is achieved, but pressure drop across the filter element increases
Solution Approach 1:
The patent introduces structural embossments with varying depths, angles, and orientations on the filter media surface, transforming a two-dimensional flat surface into a three-dimensional structured surface. This dimensional change creates multiple flow paths and reduces resistance to fuel flow while maintaining water coalescence functionality through the embossed geometric features that guide water droplet movement
Solution Approach 2:
The filter media is designed with non-uniform embossment patterns where different regions have embossments with specific geometries, angles, and orientations optimized for local flow conditions. This local quality variation allows different areas of the filter element to address specific flow patterns and water coalescence needs, reducing overall pressure drop while maintaining effective separation
2Ease of manufacture
If embossments are pressed parallel to machine direction, then manufacturing is simplified, but embossment contact area with water droplets is reduced
Solution Approach 1:
The patent employs asymmetric embossment designs where the embossment axes are oriented at specific angles relative to the machine direction and fold lines, rather than being parallel to them. This asymmetry increases the effective contact area between embossments and water droplets by creating surfaces that are more favorably oriented for droplet interception and coalescence, while still being manufacturable through conventional embossing processes
3Ease of operation
If water droplets flow parallel to central axis, then gravitational drainage is simplified, but water concentration increases at the bottom of the element
Solution Approach 1:
The embossment patterns are designed with varying orientations and angles in different regions of the filter element. In upper regions, embossments may be oriented to promote downward gravitational flow, while in lower regions, the embossment geometry and orientation are modified to disperse water droplets and prevent excessive concentration at the bottom, addressing local water accumulation problems through spatially varying structural properties
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 effectively reduces pressure drop across the filter element while maintaining efficient water coalescence and separation, ensuring uniform water distribution and improved filtration performance throughout the element.
Implementation Method 1
coalesce (combine) highly dispersed, emulsified water particles into larger water drops
Implementation Method 2
facilitate gravitational water flow
Implementation Method 3
reduce the pressure drop across a filter element
Data Source
AI summary
A filter media, filter element, filter system and methods are provided. The filter media provides improved filter characteristics including water separation efficiency. The filter media may include one or more of increased surface roughness and/or embossments. The filter media may be provided by pleated filter media.