Hopper-Shaped Filter Media Retainer Plate Scaling Prevention
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Solution Overview
Problem
Conventional filter systems with multiple plates are prone to clogging due to biological and chemical scaling, leading to increased pressure drop and system failure, and require additional scouring particles, increasing cost and complexity.
Innovation Solution
A filter system with a single filter media retainer plate featuring hopper-shaped compartments and baffles that direct backwash fluid vertically to scour the plate surface, preventing scaling and eliminating the need for separate scouring particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat media retainer plate with slots is used to support filter media, then the filter media is retained and particles are captured, but biological and chemical scaling adheres to the plate surface, clogging the water pathways and increasing pressure drop
Solution Approach 1:
The patent applies curvature by transitioning from a flat plate surface to a hopper-shaped compartment design with sloped walls. This curved/sloped geometry prevents biological and chemical scaling from adhering and clogging the water pathways, as the scaled material cannot establish a stable attachment on the inclined surfaces.
Solution Approach 2:
The patent converts the harmful effect of scaling into a beneficial scouring action. During backwash operation, the accumulated scaling and filter media are fluidized and directed against the plate surface, using the harmful scaling material itself to clean and prevent further scaling buildup on the hopper-shaped surfaces.
2Strength
If multiple plates are used in the filter media assembly, then structural support is provided, but the cost and assembly complexity increase significantly
Solution Approach 1:
The patent merges multiple functions into a single integrated plate structure. The hopper-shaped compartment plate combines media retention, structural support, and scaling prevention functions that were previously distributed across multiple separate plates, thereby reducing assembly complexity and cost while maintaining structural integrity.
Solution Approach 2:
The single hopper-shaped plate performs multiple functions: it supports and retains the filter media, provides structural strength to the assembly, prevents scaling through its sloped geometry, and facilitates backwash distribution. This multi-functionality eliminates the need for additional specialized plates.
3Object-affected harmful factors
If separate scouring particles are added to prevent scaling, then the plate surface is cleaned, but the cost and complexity of the filter system increase
Solution Approach 1:
The system achieves self-service scaling prevention by utilizing its own backwash operation. The backwash fluid fluidizes the filter media and directs it against the plate surfaces, enabling the filter media itself to perform the scouring function that would otherwise require separate scouring particles, thereby eliminating additional material costs and system complexity.
Solution Approach 2:
The filter media serves dual functions: filtering particles from the water during normal operation and scouring the plate surfaces during backwash operation. This multi-functionality eliminates the need for separate scouring particles, reducing both material quantity and system complexity.
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 system effectively reduces costs and assembly complexity by using a single plate design and integrated scouring mechanism, preventing clogging and maintaining system efficiency without additional scouring particles.
Implementation Method 1
the baffle is adapted to direct a backwash fluid in a vertical direction through the slot so that the backwash fluid actuates the filter media to scour the top surface of the filter media retainer plate
Implementation Method 2
the filter media captures the particles, such as dirt, from the liquid as the liquid passes through the filter media
Implementation Method 3
the backwash fluid actuates the filter media to scour the top surface of the filter media retainer plate and prevent the build-up of biological and/or chemical scaling
Data Source
AI summary
A filter system for filtering a liquid containing particles including a single media retainer plate having a top and bottom surface, and defining at least one hopper-shaped compartment having a sloped wall defining a slot spanning the top and bottom surfaces is disclosed. The plate also includes at least one baffle extending from the bottom surface and filter media disposed on the top surface. During a filtering operation of the filter system, the filter media captures the particles, such as dirt, from the liquid as the liquid passes through the filter media to an underdrain system. During a backwash operation of the filter system, the baffle is adapted to direct a backwash fluid in a vertical direction through the slot so that the backwash fluid actuates the filter media to scour the top surface of the plate and prevent the build-up of biological scaling on the plate.