Pleated Support Backing Filter for Industrial Coating
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Solution Overview
Problem
Current air filtration systems in industrial coating applications, such as automotive painting, face challenges in achieving high paint retention efficiency while maintaining a low pressure drop and requiring frequent filter replacements to meet stringent environmental standards.
Innovation Solution
A filter design featuring a corrugated paperboard or plastic housing with a pleated support backing and slit and expanded paper filtration media, allowing for efficient air flow and effective particle retention without significant pressure drop, and allowing for easy assembly and disassembly for reduced maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screening filters with smaller pores are used to increase paint retention efficiency, then filtration efficiency is improved, but pressure drop increases substantially and filters clog rapidly requiring frequent replacement
Solution Approach 1:
The filter media is segmented into multiple layers with different pore sizes. The upstream layer has larger pores to maintain low pressure drop, while downstream layers have progressively smaller pores to achieve high paint retention efficiency. This layered segmentation allows the filter to capture particles of various sizes without causing substantial pressure drop or rapid clogging.
Solution Approach 2:
Different regions of the filter media have different pore sizes tailored to local filtration needs. The upstream portion handles coarse particle removal with larger pores, while downstream portions handle finer particles with smaller pores. This local quality variation optimizes both pressure drop and filtration efficiency across different stages of the filtration process.
2Reliability
If filters are designed to meet stringent environmental standards with high arrestance efficiency, then paint retention is improved, but filters require more frequent replacement due to rapid filling with overspray
Solution Approach 1:
The filter is segmented into multiple layers that progressively capture particles of different sizes. This allows the filter to meet high arrestance efficiency requirements while distributing the particle capture load across multiple layers, preventing rapid saturation of any single layer and extending overall filter service life.
Solution Approach 2:
The filter uses variable pore sizes across different layers rather than a uniform pore size. This parameter change allows the filter to achieve high efficiency for fine particles in downstream layers while upstream layers with larger pores handle the bulk of particle capture, delaying saturation and extending service life.
3Ease of manufacture
If conventional filter designs are used, then initial setup is simple, but operational costs increase due to frequent filter replacements
Solution Approach 1:
The filter employs a multi-layer segmented design that can be manufactured using standard filtration manufacturing processes. Each layer can be produced independently and then assembled, maintaining ease of manufacture while achieving extended service life and reduced operational costs through improved particle capture efficiency across multiple stages.
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 filter achieves high paint retention efficiency with a low pressure drop, reducing the need for frequent replacements and lowering operational costs, thus enhancing the efficiency and cost-effectiveness of industrial coating filtration systems.
Implementation Method 1
The support backing has at least a first substantially planar panel joined at a first edge to a first edge of a second substantially planar panel... The first and second panels have openings formed therethrough to provide substantially no resistance to the flow of gas through the panels
Implementation Method 2
Filtration material is attached to the support backing... achieving high paint retention efficiency with a low pressure drop
Data Source
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AI summary
A filter for industrial coating filtration systems. The filter has a housing made up of a peripheral wall extending around the periphery. The housing is preferably made of a suitably rigid material. A preferably rigid support backing is mounted within the housing. The support backing has a planar configuration with openings formed through it so that gas can flow through without substantial resistance. The preferably planar sheet of which the support backing is made is pleated. The pleated support backing defines a series of panels, each of which is angled to a next adjacent panel. Filtration media is mounted to the support backing, end caps are attached to the ends of the support backing to maintain the pleated configuration, and the assembly is inserted into the housing, which can have end flaps to seal using tape or adhesive.