Pleated Filter Media With Inverted Pleats and Spacing Elements
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Solution Overview
Problem
Pleated filtration media are prone to deflection and masking, which reduces their surface area and operational efficiency, and existing methods to prevent these issues are costly, complex, or lack versatility.
Innovation Solution
A pleated media pack design with a scoring pattern that allows for the formation of major and minor pleats, along with indentations, which provides structural stiffness, flexibility, and compressibility, enabling efficient fluid flow and reducing the need for adhesive attachment between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If pleated filtration media are used to maximize surface area, then the filtration surface area increases, but the media becomes prone to deflection and masking
Solution Approach 1:
The filtration media is divided into multiple pleats that are separated by spacing elements. Each pleat acts as an independent segment, preventing deflection from propagating across the entire structure. The spacing elements create discrete segments between adjacent pleats, maintaining individual pleat stability while preserving high surface area.
Solution Approach 2:
The filtration system combines the pleated filtration media with spacing elements to create a composite structure. The spacing elements provide structural support and rigidity to the otherwise flexible pleated media, preventing deflection and masking while allowing the media to maintain its high-surface-area pleated configuration.
2Area of moving object
If deep pleats are used to increase surface area density, then the filtration efficiency improves, but masking between adjacent pleats increases
Solution Approach 1:
Spacing elements are introduced as intermediary components between adjacent deep pleats. These elements act as mediators that maintain the necessary separation distance, preventing the pleats from touching and causing masking while allowing the pleats to maintain their deep configuration for high surface area density.
Solution Approach 2:
The spacing elements extend the structure into a third dimension by protruding between the pleats. This dimensional addition creates physical separation in the radial direction, preventing masking between adjacent deep pleats while preserving the deep pleat configuration for maximum surface area density.
3Stability of the object's composition
If structural supports are added to prevent deflection, then the structural integrity improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The spacing elements are designed as thin, flexible components that can be easily integrated into the pleated structure. These thin-film spacing elements provide the necessary structural support to prevent deflection while maintaining manufacturing simplicity and cost-effectiveness, avoiding the need for complex rigid support structures.
Solution Approach 2:
The spacing elements are designed to be self-positioning and self-supporting within the pleated structure. They automatically maintain the correct spacing and provide structural support without requiring complex assembly procedures or additional fastening mechanisms, thereby reducing manufacturing complexity while improving structural integrity.
4Stability of the object's composition
If adhesive attachment is used to retain spacing between pleats, then the structural stability improves, but the manufacturing cost and complexity increase
Solution Approach 1:
The adhesive attachment step is extracted and eliminated from the manufacturing process. The spacing elements are designed to provide structural stability through their geometry and mechanical interlocking with the pleats, rather than through adhesive bonding. This removes the need for costly and complex adhesive application and curing processes.
Solution Approach 2:
The spacing elements are designed as simple, inexpensive components that provide adequate spacing stability without requiring permanent adhesive attachment. Their simple geometry allows for easy manufacturing and integration, reducing both material and processing costs while maintaining functional stability.
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 design enhances the structural integrity and flexibility of filtration media, minimizing masking and pressure drop, while allowing for cost-effective manufacturing and increased filtering efficiency.
Implementation Method 1
folded sheet material that is configured to maintain a degree of structural integrity when exposed to fluid streams
Implementation Method 2
A1, a section of filtration media is folded in the pleats, with at least some pleats having a major pleat depth
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A pleated media pack includes a section of media configured into a tube defining an interior volume and an open opening at one end. A ratio of the pleat depth to a diameter of the opening is greater than 0.2. At least some of the pleats at one end of the media pack are inverted. In some examples, the pleats include major pleats alternating with minor pleats.