Pleated Single Phase Filter Coalescer Element
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Solution Overview
Problem
Existing filtration devices for oil-based industrial liquids, such as those used in turbines, face challenges with complex construction, high flow resistance, and inadequate removal of free and emulsified water, failing to meet modern industrial equipment specifications.
Innovation Solution
A single-phase filter coalescer element with a rigid support tube and a dual-function pleat block made from integrated multilayer material, including porous support layers and synthetic microfiber media, which filters particles and coalesces water, combined with a hydrophobic drainage layer to efficiently remove contaminants through a compact, lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two phase filter coalescer with pleated inner pre-filter and cylindrical outer sleeve is used, then particulate filtration and water removal are achieved, but device complexity increases and flow resistance increases
Solution Approach 1:
The patent combines the pre-filter and coalescer functions into a single integrated element. The pleated filter media serves dual purposes: filtering particulates and coalescing water, eliminating the need for separate inner pre-filter and outer sleeve components. This merging reduces device complexity while maintaining contaminant removal effectiveness.
Solution Approach 2:
The single pleated element performs multiple functions simultaneously - it acts as both a particulate filter and a water coalescer. The same pleated media structure that captures particles also provides the surface area and capillary action needed for water coalescence, making the device more versatile and less complex.
2Reliability
If a two phase filter coalescer with multiple components is used, then filtration and coalescence functions are provided, but flow resistance increases
Solution Approach 1:
By merging the pre-filter and coalescer into one integrated pleated element, the patent eliminates the flow resistance associated with multiple sequential components. The single continuous pleated structure provides a more streamlined flow path, reducing pressure drop while maintaining effective contaminant removal.
Solution Approach 2:
The pleated structure expands the filtering and coalescing surface area into a compact radial configuration. This dimensional arrangement increases the effective surface area for contaminant capture without proportionally increasing flow resistance, as the flow passes through the pleats in a radial pattern rather than through multiple linear stages.
3Reliability
If conventional filter coalescers are used, then some water removal is achieved, but emulsified water removal is insufficient
Solution Approach 1:
The pleated filter media utilizes porous materials with specific pore size distributions that enhance capillary action. The porous structure provides numerous nucleation sites for water droplet formation and coalescence, improving the ability to extract both free and emulsified water from the hydraulic fluid.
Solution Approach 2:
The patent optimizes parameters such as pleat density, media thickness, pore size distribution, and surface chemistry to enhance water coalescence efficiency. These parameter changes increase the media's affinity for water and improve coalescence kinetics, enabling more effective removal of emulsified water compared to conventional designs.
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 increased coalescing area and efficiency in removing water, improved particulate filtration, reduced flow resistance, and a simpler design, enhancing the longevity of equipment and reducing maintenance costs while meeting stringent industrial specifications.
Implementation Method 1
A hydrophobic drainage layer is disposed around and covers at least a portion of the exterior surface of the support tube
Implementation Method 2
droplets grow further into drops having a sufficient size that gravity causes the same to fall from the exterior surface of the drainage layer
Implementation Method 3
a rigid support tube having an exterior surface, a hollow interior and a porous sidewall through which an industrial liquid flows
Implementation Method 4
a synthetic microfiber media layer having a downstream face abuttingly connected with the upstream face of the first support layer, and being configured from non-woven synthetic microfibers, and having a thickness and a surface density sufficient to filter particles from the incoming industrial liquid
Implementation Method 5
at least one synthetic fiber media layer having a downstream face abutting and connected with the upstream face of the microfiber media layer, and configured from non-woven synthetic fibers, having a thickness and a surface density sufficient to continue water coalescence in the incoming industrial fluid
Data Source
AI summary
A filter coalescer element for oil based industrial fuels includes a rigid, porous support tube, and a hydrophobic drainage layer covering the outer surface of the same. A single phase, dual function combination water coalescer and particle filter pleat block is positioned in the support tube, and is formed from a multilayer material having a first porous support layer, a synthetic microfiber layer, a synthetic fiber media layer and a second porous support layer. As the fluid passes through the pleat block, solid particles are physically filtered therefrom, and water is coalesced into droplets which pass from the pleats directly through the support tube and directly into the drainage layer, where the droplets grow into a size sufficient that they fall under gravity to the bottom of the element for collection.