Overspray Filter Modules With Selective Element Replacement
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Solution Overview
Problem
Existing filter modules for overspray face challenges with high disposal effort due to numerous assembled parts and contamination issues, while reusable modules suffer from surface texture alteration and limited heat resistance, affecting filter efficiency.
Innovation Solution
A method for forming a filter module where only specific elements like the filter insert are replaced, with the housing and support frame reused, allowing for pyrolysis-resistant materials and simplified disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If disposable filter modules are used, then filter replacement is simple, but disposal effort and waste increase significantly
Solution Approach 1:
The filter module is divided into separable components: a reusable housing area and replaceable filter elements (inertial separator and filter insert). This segmentation allows selective replacement of only the contaminated filter elements while reusing the housing, reducing waste compared to disposing of entire filter modules.
Solution Approach 2:
The invention enables recovery and reuse of the housing area after the filter elements are replaced. The housing is cleaned and reused for subsequent filter elements, while only the spent filter elements are discarded for pyrolysis processing, optimizing resource utilization.
2Ease of repair
If reusable filter modules undergo pyrolysis cleaning, then filter elements can be reconditioned, but surface texture is altered and heat resistance limits filter media selection
Solution Approach 1:
The filter module is segmented into a reusable housing and disposable filter elements. This allows the filter elements to be replaced rather than subjected to pyrolysis, preserving the housing surface texture while enabling efficient disposal of contaminated filters through pyrolysis of the entire element.
Solution Approach 2:
The filter elements are designed as disposable components that are replaced rather than reconditioned through pyrolysis. This eliminates surface texture alteration issues while allowing optimal filter media selection without heat resistance constraints.
3Reliability
If entire filter modules are replaced, then filter efficiency is maintained, but disposal costs and waste increase
Solution Approach 1:
The filter module is segmented into a reusable housing area and replaceable filter elements. Only the filter elements (inertial separator and filter insert) are replaced when efficiency declines, while the housing is reused, significantly reducing disposal material compared to replacing entire modules.
Solution Approach 2:
The housing area is recovered and reused after filter element replacement, while only the spent filter elements are discarded. This selective discarding and recovering approach maintains filter efficiency through element replacement while minimizing disposal material.
4Ease of repair
If pyrolysis heat is applied to filter modules with external housing, then surface filter medium is cleaned, but outer housing absorbs heat reducing pyrolysis efficiency
Solution Approach 1:
The filter elements are extracted from the housing area before pyrolysis processing. This removes the heat-absorbing housing from the pyrolysis process, allowing direct and efficient heat application to the filter elements for complete decomposition and cleaning.
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 approach reduces disposal costs and optimizes filter efficiency by selectively replacing components, ensuring effective pyrolysis without altering the surface texture and minimizing waste.
Implementation Method 1
pyrolysis cleaning can be used to recondition the filter modules
Data Source
Figure 1
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AI summary
A method for forming a filter module (1) in a filter system, wherein the filter system has a housing region (100) of the filter module, in particular a housing region closed on the circumference, as a section of an overspray discharge channel of the filter system, comprising the following steps: A decoupling (201) of a loaded inertial separator (50) from the housing region (100) of the overspray filter system; B separate removal (202) of a loaded filter insert (1) with a loaded surface filter medium (12) and a support grid frame (2) and/or a support frame (102) from the housing region (100); C insertion (203) of a new filter insert or insertion of a filter insert with a new surface filter medium and the support grid frame (12) and/or the support frame (102); and D placing and/or inserting (204) a new inertia filter or the loaded inertia filter onto or into the housing area (100) with the inserted filter insert (1).