Pleated Filter Element Bonding for High Temperature

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Solution Overview

Problem

Existing air filter technologies fail to effectively maintain pleat shape and filtration efficiency in high-temperature applications such as cement kilns, where traditional adhesives and stiffening methods are inadequate for prolonged exposure to temperatures above 500°F and periodic back-pulsing.

Innovation Solution

A pleated filter element comprising a fibrous support layer and a filtration layer, where the fibrous support layer is bonded to the filtration layer using controlled pressurized thermal mechanical interfacial layer bonding without adhesives, and a cured stiffening agent is applied to maintain pleat shape without obstructing airflow, utilizing materials like woven fiberglass and EPTFE that can withstand high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional adhesives and stiffening methods are used to bond filtration layer to support layer, then bonding is achieved, but the filter fails in high-temperature applications above 500°F

Engineering Contradiction:

Improvefilter performance in high temperatureVSAvoidadhesive degradation at high temperature

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the adhesive layer from the filter structure, eliminating the component that degrades at high temperatures. The filtration layer is bonded to the support layer through direct thermal and mechanical bonding at the interface, without any intermediary adhesive agent, thereby eliminating the reliability issue caused by adhesive degradation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a stiffening agent as an intermediary substance applied to the support layer. This stiffening agent provides structural reinforcement and maintains pleat shape without requiring adhesive bonding, and can be selected to withstand high temperatures, thus mediating between the support layer and filtration layer without degrading.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If stiffening agents are applied to maintain pleat shape, then pleat shape is maintained, but airflow is obstructed

Engineering Contradiction:

Improvepleat shape maintenanceVSAvoidairflow permeability

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The stiffening agent is applied selectively to specific regions of the support layer, particularly at the pleat bases and along the pleat structures where structural support is needed. The filtration layer remains relatively free of stiffening agent, maintaining its porous structure and airflow permeability while still benefiting from the localized structural support provided by the stiffening agent in the support layer.

Inventive Principle:

Principle #3Local quality

3Temperature

If fibrous support layer is made thicker to withstand high temperature, then temperature resistance is improved, but filter element size increases

Engineering Contradiction:

Improvetemperature withstand capabilityVSAvoidfilter element size

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The patent uses a composite structure consisting of a support layer made from high-temperature resistant materials such as fiberglass or metal mesh, combined with a filtration layer. The support layer provides the structural framework that withstands high temperatures, while the filtration layer provides the filtering function. This composite approach allows the filter to withstand high temperatures without requiring excessive thickness, as the structural support and filtration functions are distributed across different layers with optimized material properties.

Inventive Principle:

Principle #40Composite materials

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 provides enhanced filtration efficiency and durability by maintaining pleat shape and airflow permeability in high-temperature environments, ensuring effective particulate removal and extended filter lifespan in applications like cement kilns.

Implementation Method 1

The fibrous support layer and the filtration layer are bonded together by controlled pressurized thermal mechanical interfacial layer bonding

Methodology Applied

Scientific EffectThermal mechanical bonding:

Implementation Method 2

A cured stiffening agent is applied to the fibrous support layer, with the pleated form being maintained

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS11819793B2Pleated filter designs and components therefor for elevated temperature application

Publication Date: 2023.11.21 PARKER INTANGIBLES LLC

AI summary

A filter includes a pleated filter element having a fibrous support layer and a filtration layer bonded to the fibrous support layer. The fibrous support layer and the filtration layer are both in pleated form to provide a plurality of pleats. A cured stiffening agent is applied to the fibrous support layer, and the pleated form is maintained. The fibrous support layer is bonded to the filtration layer by other than the cured stiffening agent.