Reusable Overspray Filter Module With Disposable Linings
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Solution Overview
Problem
Existing disposable filter modules for overspray separation in paint booths generate significant waste and resource consumption due to their large size and the need for frequent replacement, leading to cumbersome and expensive disposal.
Innovation Solution
A reusable and cleanable frame with disposable components, such as filter elements and linings, is used to collect overspray, allowing the frame to be reused while the disposable components are replaced when full, reducing waste and resource consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If disposable filter modules are used for overspray separation, then overspray can be effectively collected, but large quantities of waste are generated and disposal becomes cumbersome and expensive
Solution Approach 1:
The filter module is divided into two distinct segments: a reusable frame structure and disposable filter elements. This segmentation allows the frame to be recovered and reused multiple times, while only the contaminated filter elements are disposed of, significantly reducing waste quantity compared to disposing of the entire filter module.
Solution Approach 2:
The invention implements a discard-and-recover strategy where the frame is recovered and reused after the filter elements are replaced. This approach maintains reliable overspray separation while minimizing waste by recovering the majority of the module's structure.
2Ease of operation
If disposable filter modules are used, then overspray collection is simplified, but resource consumption for producing new modules increases
Solution Approach 1:
By segmenting the module into frame and filter elements, the invention reduces resource consumption since only the filter elements need to be manufactured anew for each replacement, while the frame continues to serve multiple cycles.
Solution Approach 2:
The frame is recovered and reused, directly reducing the resource consumption associated with manufacturing complete new filter modules while maintaining operational simplicity.
3Object-affected harmful factors
If the entire filter module is disposed of, then contamination of the frame is avoided, but waste and cost increase significantly
Solution Approach 1:
The contaminated filter elements are extracted and removed from the frame, allowing the frame to be separated from the contamination source. This enables the frame to be cleaned and reused without being disposed of along with the contaminated components.
Solution Approach 2:
Only the contaminated filter elements are discarded, while the frame is recovered, cleaned, and reused. This selective discarding approach minimizes waste volume while effectively managing contamination.
4Reliability
If filter modules are frequently replaced, then filtration performance is maintained, but operational costs and disposal burden increase
Solution Approach 1:
Segmenting the module allows rapid replacement of only the filter elements while retaining the frame, maintaining filtration performance without the full disposal and replacement burden of traditional modules.
Solution Approach 2:
The frame is recovered and reused across multiple filtration cycles, reducing the frequency and burden of complete module replacements while maintaining reliable filtration performance through regular filter element changes.
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 minimizes waste and resource consumption by enabling the reuse of the frame and targeted disposal of contaminated components, improving filtration efficiency and reducing operational costs.
Implementation Method 1
a plurality of filter elements for separating overspray from the air
Implementation Method 2
all the surfaces of the frame which are exposed to the air flow upstream of the first filter stage are provided with the linings such that the surfaces of the frame are protected against overspray
Data Source
AI summary
A filter module, including a plurality of filter elements for separating overspray from an air flow, the filter module including a reusable and cleanable frame configured as a support structure for components for collecting overspray, and a plurality of components inserted into the frame for collecting overspray, wherein the components for collecting overspray are at least filter elements and linings in the frame, which are configured as disposable, single-use products the filter elements form at least a first filter stage, and all the surfaces of the frame which are exposed to the air flow upstream of the first filter stage are provided with the linings such that the surfaces of the frame are protected against overspray.