Modular Filter Unit With Sealed Spacers for Scalable Filtration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter modules and capsules have complex and expensive multi-layer structures, limited scalability due to high backpressure, and require different module heights for scale-up and scale-down, making them complicated and costly.
Innovation Solution
A filter unit with integrated inflow and outflow channels is created using a single filter sheet and spacers, where the spacers are sealed on their outer faces, allowing for a compact, scalable design that can be produced simply and inexpensively, with the option to wind up the filter units for increased capacity without increasing filter layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer structure of filter sheets is used, then filtration performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The filter module is divided into multiple filter units, each consisting of a single filter sheet with integrated spacers. These modular filter units can be stacked to achieve the desired filtration performance without requiring complex multi-layer structures within each unit. The segmentation allows simple single-layer units to be combined into a high-performance system.
Solution Approach 2:
The invention uses composite spacer structures combining permeable and impermeable regions in a single spacer element. The spacers have draining regions with permeable structure and sealing regions with impermeable structure, creating a composite component that performs multiple functions (drainage and sealing) without requiring multiple separate layers.
2Device complexity
If the inner wall of the filter housing forms the inlet or outlet channel, then the structure is simplified, but dead space increases and filtration performance decreases
Solution Approach 1:
The spacers extend in the vertical dimension from the filter sheet toward the housing wall, creating three-dimensional flow channels. This vertical extension eliminates dead space by providing continuous drainage paths from all areas of the filter sheet, including regions that would otherwise be adjacent to the housing wall.
Solution Approach 2:
The spacers act as intermediary structures between the filter sheet and the housing wall. They create dedicated flow channels that mediate the transition from the filtration surface to the inlet/outlet ports, preventing direct contact between the housing wall and the filter medium while maintaining structural support.
3Productivity
If modules are connected in parallel or series for scale-up, then filtration capacity increases, but backpressure increases and system complexity increases
Solution Approach 1:
Each filter unit is designed as an independent modular element with its own integrated flow channels and spacers. Multiple units can be connected in parallel without requiring additional interconnecting channels or complex sealing arrangements, as each unit is self-contained. This segmentation allows capacity scaling while maintaining low backpressure through parallel flow paths.
4Adaptability or versatility
If different module heights are used for scale-up and scale-down, then flexibility is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The filter module uses standardized, interchangeable filter units that can be stacked in varying numbers to achieve different overall heights and capacities. Each unit has uniform dimensions and connection interfaces, allowing flexible configuration without requiring custom manufacturing for different scale requirements. The same basic unit design serves all scaling needs.
Solution Approach 2:
The spacers are designed with universal functionality, featuring both draining and sealing regions that perform multiple functions within a single component. This multi-functionality reduces the number of different component types needed, simplifying manufacturing while maintaining adaptability for various applications and scales.
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 enhances filtration and adsorption performance, allows for nearly unlimited scaling without backpressure limitations, and results in a more compact filter capsule with higher binding capacity per unit volume, enabling flexible and cost-effective production.
Implementation Method 1
a first spacer adjacent to the media side and a second spacer adjacent to the permeate side, the spacers being designed with a draining action
Implementation Method 2
at least one filter sheet
Implementation Method 3
the first spacer is designed to be impermeable to liquid on its outer face directed away from the filter sheet and is sealed off at its boundary to the outlet end, and the second spacer is designed to be impermeable to liquid on its outer face directed away from the filter sheet and is sealed off at its boundary to the inlet end
Data Source
AI summary
Filter module and filter unit with an inlet for medium that is to be filtered, and with an outlet for the permeate, with at least one filter sheet, a first spacer adjacent to the media side and a second spacer adjacent to the permeate side, the spacers being designed with a draining action, and the first spacer being connected to an inlet and the second spacer to an outlet, wherein the at least one filter sheet forms a first filter unit together with the two adjacent spacers, the filter sheet is designed as a single filter or a filter stack, the first spacer is designed to be impermeable to liquid on its outer face directed away from the filter sheet and is sealed off at its boundary to the outlet end, and the second spacer is designed to be impermeable to liquid on its outer face directed away from the filter sheet and is sealed off at its boundary to the inlet end.