Modular Filter Frame Axial Stacking Segmentation
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Solution Overview
Problem
Existing filter elements face premature damage and reduced lifespan due to direct impurity binding on the filter media, leading to frequent cleaning or replacement, and inefficient filtration processes.
Innovation Solution
A modular filter element frame with an elongate body featuring smooth-ended lobes and apertures, allowing axial stacking for customizable length, and a thermoplastics material construction for improved durability and flow efficiency, along with a filter sleeve that extends along the outer periphery to prevent snagging and enhance filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter aid is used to form a filter cake on the filter media, then filtration efficiency and filter media lifespan are improved, but the filter element structure becomes more complex and requires additional pre-coating equipment
Solution Approach 1:
The filter element is divided into modular segments that can be stacked axially. Each module contains integrated support ribs and channels that provide structural support while accommodating filter aid application, eliminating the need for complex external support structures
Solution Approach 2:
The filter element frame is designed to perform multiple functions: providing structural support, facilitating filter aid application, enabling modular assembly, and supporting the filter media. The integrated design combines what would traditionally be separate components into a single multi-functional unit
2Ease of manufacture
If filter elements are made with fixed length, then manufacturing is simpler, but adaptability to different filtration requirements is reduced
Solution Approach 1:
The filter element is divided into identical modular segments that can be stacked in varying quantities to achieve different total lengths. Each segment is manufactured using the same injection molding process, maintaining manufacturing simplicity while enabling length customization through simple axial stacking of standardized units
Solution Approach 2:
The filter element length is made adjustable through the modular stacking design, allowing the system to adapt to different filtration requirements by varying the number of axial segments, transforming a static fixed-length design into a dynamic configurable system
3Device complexity
If filter media is directly exposed to impurities without filter aid, then the filtration process is simpler, but the filter media becomes blinded or damaged requiring premature cleaning or replacement
Solution Approach 1:
The filter aid is applied to the filter media surface before the actual filtration process begins, creating a protective filter cake that prevents impurities from directly contacting and damaging the filter media. This preliminary protective layer extends filter media lifespan by preventing blinding and damage during operation
Solution Approach 2:
The filter aid acts as an intermediary substance between the impurities in the liquid and the filter media. Instead of impurities directly contacting the filter media, they are first captured by the filter aid layer, which serves as a protective mediator that preserves the filter media integrity
4Ease of operation
If single-piece filter elements are used, then assembly is simpler, but adaptability to different axial length requirements is reduced
Solution Approach 1:
The filter element is segmented into modular units with standardized connection interfaces that can be easily assembled axially. The segmentation maintains assembly simplicity through standardized mating features while providing adaptability by allowing different numbers of segments to be combined to meet various length requirements
Data Source
AI summary
A modular filter element frame (10) and a filter element frame assembly (100, 150) are disclosed. The filter element frame (10) has an elongate body (12) with a central bore (14) extending axially through the body. In cross-section the body has at least three smooth-ended lobes (16) that extend radially therefrom. The lobes are angularly spaced about the central bore such that a longitudinally extending channel (18) is formed along the body between adjacent lobes. Each channel has a plurality of longitudinally spaced apertures (20) extending into the central bore. Axially outer ends (24, 28) of the body are adapted to enable axial stacking thereof with like modular filter element frames to cooperatively form a filter element frame assembly (100, 150) with a required axial length. The assembly may receive a filter sleeve such that the sleeve extends at least partially along an outer periphery thereof.