Pleated Filter Element With Offset Structural Layers
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Solution Overview
Problem
Existing filter elements face challenges in stabilizing pleats during operation due to forces acting on them, which can lead to bypass formation and reduced contaminant retention capacity.
Innovation Solution
The filter element incorporates additional structural layers positioned at axial distances from each other along the filter mat, with some layers welded to end caps to concentrate material and enhance stability, while maintaining flexibility and reducing overall volume, allowing for increased space between pleats for contaminant retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional structural layers are embedded together with the main structural layer at a common end into an end cap, then the filtering properties are optimized with pre-filters having greater filter fineness, but the pleats lack stabilization against forces acting during filter operation
Solution Approach 1:
The filter element is segmented into multiple functional zones: the main structural layer provides filtration throughout its length, while additional structural layers are strategically positioned at specific segments (end caps and optionally center) to provide stabilization only where needed. This segmentation allows different parts of the filter mat to serve different functions - filtration in the main body and stability at the ends where pleats are most vulnerable to deformation during operation.
2Stability of the object's composition
If additional structural layers are added to stabilize pleats, then pleat stability is improved, but the overall volume of the filter mat increases reducing space for contaminant retention
Solution Approach 1:
Instead of uniformly thickening the entire filter mat to stabilize pleats, the invention applies additional structural layers locally only at specific positions where stabilization is needed - namely at the end caps and optionally at the center. This localized approach provides the necessary pleat stability while minimizing the overall volume increase, preserving space between pleats for contaminant retention and maintaining the filter's overall efficiency.
3Strength
If material is concentrated at end caps to stabilize pleats, then embedding of filter mat into end caps is improved, but the flexibility of filter mat sections between end caps is reduced
Solution Approach 1:
The filter mat is divided into distinct segments with different functional characteristics: the end cap regions contain additional structural layers that provide strong embedding and pleat stabilization, while the central sections maintain only the main structural layer, preserving flexibility and adaptability. This segmentation allows each region to optimize its specific function - the ends provide stable anchoring while the middle sections remain flexible for effective filtration and contaminant capture.
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
This configuration provides enhanced pleat stability, reduced bypass risk, and increased flow-exposed surface area, while maintaining effective contaminant retention and fluid permeability.
Implementation Method 1
At each of the two end caps, an additional structural layer each is welded at one end together with the respective end of the main structural layer into the corresponding end cap
Data Source
AI summary
A filter element has a pleated filter mat (3). The terminal axial ends (7, 8) of the mat are connected to end caps (9, 11). The mat has a main structural layer (15) having filtering properties and a first additional structural layer and a second additional structural layer (17,19). The surface area of each of the additional structural layers (17, 19) is smaller than the surface area of the main structural layer (15). The axial ends (12, 14) of one additional structural layer (17) is located at an axial distance from the axial ends (16, 18) of the other additional structural layer (19) on the filter mat (3).