Joined Filter Media Pleat Packs With Interleaved Seams
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Solution Overview
Problem
Existing filter designs face a trade-off between efficiency in removing particulate matter and pressure drop, with increased efficiency often leading to higher pressure drops and energy consumption, necessitating a need for improved filtering efficiencies with lower initial pressure drop performance.
Innovation Solution
A joined filter media pleat pack assembly is developed, comprising multiple pleat packs with interleaved or mitered pleats and seams, where the pleats of one pack are nested with those of adjacent packs, and terminal edges are mitered at complementary angles, optionally sealed with adhesive, allowing for improved pressure drop performance by reducing the seam dimension and enabling larger frame openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media efficiency is increased to remove small particles, then filtering efficiency is improved, but pressure drop increases leading to higher energy consumption
Solution Approach 1:
The filter assembly is divided into multiple separate pleat packs (at least two) that are joined together. Each pleat pack can be independently manufactured and optimized, then assembled into a complete filter assembly. This segmentation allows for optimization of filtering efficiency in each pleat pack while managing overall pressure drop through the distributed structure.
Solution Approach 2:
The pleats of adjacent pleat packs are nested together in an interleaved arrangement, where pleats from one pack fit between pleats of adjacent packs. This nesting creates a compact assembly that maximizes filtering surface area while minimizing the overall footprint and reducing flow resistance, thereby lowering pressure drop for a given filtering efficiency.
2Reliability
If filter media efficiency is increased to remove small particles, then filtering efficiency is improved, but pressure drop increases
Solution Approach 1:
The filter design transitions from a single-plane filter structure to a three-dimensional nested arrangement of multiple pleat packs. By stacking pleat packs in multiple layers with interleaved pleats, the design increases the effective filtering surface area in the vertical dimension, distributing the pressure drop across multiple stages rather than concentrating it in a single filter media layer.
Solution Approach 2:
The filter assembly combines multiple filter media pleat packs into a composite structure, where each pleat pack may use different filter media configurations or orientations. This composite approach allows optimization of particle capture efficiency while managing pressure drop through the combined effect of multiple filtering stages.
3Ease of manufacture
If conventional seam structures are used to join pleat packs, then manufacturing is simplified, but seam dimension increases reducing frame opening size
Solution Approach 1:
The pleats of adjacent pleat packs are nested together in an interleaved arrangement, where the pleats fit within each other's spaces. This nesting eliminates the need for large external seam structures, as the pleats themselves interlock to form the joint. The result is a compact seam with minimal dimension perpendicular to the seam length, maximizing the usable frame opening area.
4Reliability
If multiple pleat packs are joined to increase filtering capacity, then filtering efficiency is improved, but device complexity increases
Solution Approach 1:
The filter assembly is divided into multiple standardized pleat packs that can be manufactured independently using the same processes. Each pleat pack is a modular unit with consistent dimensions and pleat configurations, making them interchangeable and simplifying the assembly process despite the multi-component nature of the complete filter.
Solution Approach 2:
Multiple pleat packs are merged into a single integrated filter assembly through the nested pleat structure. The interleaved pleats of adjacent packs create a unified filtering surface that functions as a cohesive unit, while maintaining the manufacturing and assembly advantages of separate modular components.
Data Source
AI summary
A joined filter media pleat pack assembly comprises at least two filter media pleat packs, wherein each pleat comprises a root and a crown, wherein a seam between each filter media pleat pack is at least one of: (a) structure wherein the pleats, crowns, and roots of one filter media pleat pack are interleaved or nested with the corresponding structure of an adjacent filter media pleat pack or (b) structure wherein at least a portion of the terminal edges of adjacent filter media pleat packs are mitered at complimentary angles and assembled in mating relation.