Keyed Filter Coalescer Cartridge for Higher Gas Flow Liquid Removal
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Solution Overview
Problem
Existing gas phase filter separators face challenges in optimizing flow paths and alignment, leading to inefficient liquid removal and increased aerosolization, particularly in single-stage filter cartridges.
Innovation Solution
The implementation of a filter cartridge with an inside-out flow design featuring a finger pull ledge oriented by a key to position the baffle at the bottom, directing gas flow towards the top of the cartridge, combined with a baffle at the inlet end cap to enhance liquid coalescence and reduce flux rate in the liquid-concentrated area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas flow rate is increased to handle higher production volumes, then productivity improves, but liquid removal efficiency deteriorates due to increased flux rate causing aerosolization
Solution Approach 1:
The patent applies local quality by creating different flow paths with different flux rates in different regions of the filter cartridge. The baffle structure directs flow to create a low flux rate zone in the liquid-concentrated bottom half of the cartridge, allowing efficient liquid removal without aerosolization, while the top half can handle higher flow rates. This localized differentiation resolves the contradiction between overall productivity and local liquid removal efficiency.
Solution Approach 2:
The filter cartridge is segmented into functional zones using the baffle structure. The bottom half with the baffle creates a separate flow path that is optimized for liquid coalescence and removal, while the top half handles gas flow. This segmentation allows the system to simultaneously achieve high gas flow rates and effective liquid removal by assigning different functions to different segments.
2Reliability
If more filter cartridges are used to handle the same gas flow rate, then liquid removal efficiency improves, but device complexity and cost increase
Solution Approach 1:
The patent changes the flow parameters within a single cartridge by introducing the baffle structure that creates controlled flow paths. This modifies the flux rate distribution and flow direction to optimize liquid removal efficiency, allowing a single cartridge to perform the work of multiple simpler cartridges, thereby reducing overall system complexity.
3Ease of manufacture
If filter cartridge is designed with standard flow path, then manufacturing simplicity is maintained, but liquid removal performance deteriorates due to inefficient flow through liquid-concentrated areas
Solution Approach 1:
The baffle structure introduces asymmetry to the flow path design, creating a non-uniform flow distribution that is optimized for liquid removal. The baffle is positioned to create a specific flow pattern that directs gas through the liquid-concentrated bottom half at a controlled, lower flux rate, improving liquid removal performance while maintaining manufacturing simplicity through a straightforward baffle construction.
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
This design improves liquid removal efficiency by creating larger coalesced droplets, reduces aerosolization, and allows for fewer cartridges to handle the same gas flow rate, while ensuring proper installation and orientation through keying and locking mechanisms.
Implementation Method 1
Positioning such a baffle as may be provided by the finger pull ledge, as aligned by the key, to the bottom location directs the gas flow towards the upper half of the filter cartridge internal area
Implementation Method 2
designed to coalesce liquid mist particles as the gas flows through the filter cartridge media
Implementation Method 3
As liquid mist enters the inlet port of the cartridge end cap, it will naturally settle by gravity to the bottom of the cartridge
Data Source
AI summary
A filter system comprises a pressure vessel housing with internal components designed to remove solid particles, semi-solid particles, and liquid droplets from a gas phase media. The filter housing utilizes multiple replaceable filter cartridges. The system includes a keyed filter coalescer cartridge designed to flow from the inside open area of the cartridge to the outside annular area of the housing prior to leaving the system through an outlet nozzle. The key is designed to locate a baffle of the filter cartridge inlet side end cap in a certain orientation as to provide enhanced liquid removal performance for the system. The baffle may also serve as a handle.