Pleated Filter Media Axial Flow Channels
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Solution Overview
Problem
Existing fluid filters face challenges in minimizing flow restriction and pressure drop, particularly in axial flow configurations, which can limit their efficiency and compatibility with traditional filter housings.
Innovation Solution
The development of pleated filter media with pleat segments extending in axial and transverse directions, featuring varying widths and angles, which creates axial flow channels and V-shaped or curvilinear configurations to reduce pressure drop and increase flow area, allowing for integration into standard filter housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional axial flow filter configurations are used, then filter housing compatibility is maintained, but flow restriction and pressure drop increase
Solution Approach 1:
The filter media is configured with pleats that extend in multiple dimensions (axial and transverse directions) rather than a single axial direction. This creates a three-dimensional flow path that reduces pressure drop while maintaining housing compatibility. The pleats are arranged to guide fluid flow through a combination of axial and transverse components, effectively utilizing spatial dimensions to reduce flow restriction.
Solution Approach 2:
The pleats are formed with curved or rounded configurations rather than sharp angular folds. This curvature smooths the flow paths between pleats, reducing turbulence and pressure loss. The bend lines are designed to create gentle transitions in the flow direction, minimizing energy loss while maintaining the pleated structure's space-efficient configuration.
2Loss of energy
If pleated filter media with varying widths are used, then pressure drop is reduced, but manufacturing complexity increases
Solution Approach 1:
The filter media is designed with locally varied pleat widths along its length, where different sections have different pleat dimensions optimized for their specific flow requirements. This allows pressure drop reduction in critical flow areas while maintaining simpler structures in less critical areas. The varying width is implemented through localized adjustments in the pleat formation process rather than requiring complete redesign of the entire media structure.
3Area of stationary object
If V-shaped or curvilinear pleat configurations are used, then flow area is increased, but structural support requirements increase
Solution Approach 1:
The filter media combines multiple material properties in a composite structure that provides both the necessary flexibility for V-shaped or curvilinear pleat configurations and the structural support required to maintain shape. This composite construction allows the pleats to be formed at angles that maximize flow area while the material composition provides the strength needed to prevent collapse or deformation under flow conditions.
Solution Approach 2:
The pleats are pre-formed with their V-shaped or curvilinear configurations during the manufacturing process, and seal tips are positioned in advance to maintain structural integrity. This preliminary formation and stabilization ensures that the flow-area-enhancing geometry is established before the filter is put into service, reducing the need for complex structural support during operation.
Data Source
AI summary
A pleated filter media comprises a plurality of pleats comprised of pleat segments extending in an axial direction between first and second axial ends and extending in a transverse direction that is perpendicular to the axial direction between first and second sets of pleat tips at least partially defined by first and second sets of bend lines. Axial flow channels are defined between the pleat segments in the lateral direction and the plurality of pleats has a width in the transverse direction that varies along the axial direction.