Pleated Air Filter for Bleed Valve Assembly
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Solution Overview
Problem
Existing pneumatic valve filters in bleed air systems have limited filtration capacity and micron rating, leading to rapid clogging and particle bypass due to restricted diameter and low micron ratings, resulting in decreased valve system lifespan and increased failure rates.
Innovation Solution
A valve assembly with a larger diameter air filter element and an absolute micron rating of 5 microns, featuring a pleated design and enhanced sealing system, including C-seals made of nickel alloys, to prevent leakage and bypass, and a housing configuration that maintains efficient filtration and prevents axial plug load when clogged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wire mesh or sintered metal screen filters are used in a top hat configuration with spring loading, then the valve can be compact and simple to install, but the filtration capacity is limited and the micron rating is restricted
Solution Approach 1:
The patent transitions from a two-dimensional flat filter screen to a three-dimensional pleated filter element. The pleated configuration increases the surface area of the filter by folding it into multiple layers, allowing more filtration material to be packed into the same cylindrical space. This dimensional change enables higher filtration capacity without increasing the overall valve size.
Solution Approach 2:
The filter element is designed to be nested within the cylindrical bore of the valve body. The pleated structure allows the filter to be compressed into a compact form that fits inside the existing valve housing, maximizing the use of available space while maintaining high filtration capacity.
2Length of stationary object
If wire mesh or sintered metal screen filters are used with limited diameter, then the valve remains compact, but the micron rating is limited and clogging occurs quickly
Solution Approach 1:
By folding the filter into a pleated configuration, the patent increases the effective filtration surface area by a factor of 3-5 times compared to a flat filter of the same diameter. This allows the use of finer micron ratings (5 microns absolute) without proportionally increasing the valve diameter, as the increased surface area compensates for the smaller pore size.
Solution Approach 2:
The patent changes the physical configuration parameter of the filter from flat to pleated, which increases the surface area density. This parameter change allows the system to achieve higher filtration precision (lower micron rating) within the same dimensional constraints.
3Ease of operation
If spring-loaded filter seating is used, then the filter can be easily secured, but when the filter clogs it lifts against the spring load allowing particles to bypass the filter
Solution Approach 1:
The patent removes the spring-loaded seating mechanism entirely and replaces it with a rigid retainer that mechanically secures the filter element. This extraction of the spring mechanism eliminates the problem of filter lift-off when clogged, while the retainer provides sufficient ease of installation through its simple snap-in or clamp design.
Solution Approach 2:
The filter element and housing are designed with precise cylindrical geometries that create a interference fit or mechanical retention feature. This curved, precision-fit design provides reliable sealing and retention without requiring spring pressure, preventing filter lift-off under differential pressure.
4Quantity of substance
If larger diameter filter elements are used, then filtration capacity increases, but the valve size and complexity increase
Solution Approach 1:
The pleated configuration transforms the filter from a flat two-dimensional surface to a three-dimensional structure with increased surface area density. This allows the filter to achieve high filtration capacity (equivalent to a much larger diameter flat filter) while maintaining a compact cylindrical form factor that fits within standard valve housings.
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
The solution significantly increases filtration capacity and lifespan of the valve assembly, preventing breakdowns and improving efficiency by capturing smaller contaminants and maintaining airflow, thus reducing replacement costs and ensuring better control of bleed air systems.
Implementation Method 1
filtering the bleed air through an air filter element with an absolute micron rating of 5 microns
Implementation Method 2
a first seal sealingly engaged to the filter cover and to the air filter element, a second seal sealingly engaged to the filter cover and to the air filter element, and a third seal sealingly engaged to the air filter element and a housing
Data Source
AI summary
An air filter assembly includes an air filter element with a pleated filter and seals incorporated at either end to prevent contaminants from bypassing the filter. The air filter assembly includes a filter cover, first, second and third seals, and an air filter element with a large diameter and low micron rating.