Pyramid Pleated Vacuum Filter for Air Lock Prevention
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Solution Overview
Problem
Conventional vacuum filters are bulky, prone to air lock due to air bubbles, and have high production costs, with inefficient filtration area utilization and inconvenient handling, especially when restarting filtration processes.
Innovation Solution
A vacuum filter device featuring a pyramid-shaped large area pleated filter element with a hydrophilic membrane, allowing air bubbles to move vertically away from the filter surface and using a single hydrophobic membrane for air path and restart functionality, enabling universal use with feed cups or tubes and reducing overall height and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large area filter membrane is used, then filtration efficiency is improved, but the device becomes bulky increasing packaging and storage costs
Solution Approach 1:
The filter membrane is folded into an accordion-like structure that nests within the cylindrical housing, allowing a large surface area membrane to be contained in a compact volume. The nested folds expand during filtration to provide full membrane surface area for efficient filtration while maintaining a small storage footprint.
Solution Approach 2:
The filter membrane is transformed from a flat two-dimensional surface into a three-dimensional pleated structure, increasing the surface area within the same footprint. This dimensional transformation allows the membrane to provide large filtration area while maintaining compact device dimensions for convenient storage and handling.
2Reliability
If hydrophobic zones are created on the filter membrane to prevent air bubble blockage, then air lock prevention is improved, but the filtration area is reduced
Solution Approach 1:
The air bubble removal function is extracted from the filter membrane surface by introducing a separate hydrophobic membrane at the inlet. This dedicated air removal membrane handles all air bubble evacuation needs, allowing the main filter membrane to maintain 100% hydrophilic surface for maximum filtration area without compromise.
Solution Approach 2:
A separate hydrophobic membrane acts as an intermediary component between the feed solution and the hydrophilic filter membrane. This intermediary layer captures and removes air bubbles before they reach the filtration surface, protecting the full filtration area from air lock while maintaining distinct functional zones.
3Reliability
If multiple hydrophobic membranes are sealed at various angles to prevent air lock, then air bubble removal is improved, but manufacturing cost increases
Solution Approach 1:
The air removal function is extracted and consolidated into a single hydrophobic membrane component located at the inlet, eliminating the need for multiple hydrophobic membranes sealed at various angles. This single-component approach maintains effective air bubble removal while dramatically simplifying manufacturing procedures and reducing production costs.
Solution Approach 2:
The single hydrophobic membrane at the inlet serves multiple functions: it acts as an air bubble trap, provides a seal for the inlet chamber, and facilitates easy restart of filtration after air lock conditions. This multi-functional design replaces the need for multiple specialized components, reducing manufacturing complexity.
4Productivity
If the feed funnel is refilled repeatedly from a large container, then filtration continuity is improved, but handling difficulty increases
Solution Approach 1:
The feed funnel is nested within the cylindrical housing as an integrated component, allowing the housing to serve dual purposes as both the filter element containment and the feed solution reservoir. This nested configuration eliminates the need for separate large feed containers and repeated pouring operations, improving both filtration continuity and handling convenience.
Solution Approach 2:
The feed solution storage function is merged with the filter housing structure, creating a unified device that combines filtration and feed storage in one component. This integration eliminates the need for separate feed containers and manual refilling operations, allowing continuous filtration while simplifying user handling.
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 unimpaired filtration with higher efficiency, reduced packaging and storage costs, and improved mechanical stability by allowing air bubbles to escape and facilitating easy restarts without air lock, while minimizing the number of hydrophobic membranes used.
Implementation Method 1
a vacuum filter device featuring a pyramid-shaped large area pleated filter element with a hydrophilic membrane
Implementation Method 2
using a single hydrophobic membrane for air path and restart functionality
Implementation Method 3
Vacuum filtration system
Data Source
AI summary
The present disclosure relates to a vacuum filter that incorporates a large area pleated filter element having pleated hydrophilic membrane configured along slanting surface in pyramid shape and incorporated with in a filter housing that can be accommodated in neck of a filtrate container. The disclosed configuration reduces overall height of the filtering system improving its stability and reducing space requirement. Further, top portion of the filter housing is configured to receive either a feed cup for direct feeding of feed liquid by pouring in the cup or a fitting with tube that can be used to suck the feed from a feed solution container under action of a vacuum thus allowing universal use. In another embodiment, a single hydrophobic membrane is provided to avoid problems of low flow due to bubbles coming with the feed solution and also to allow restart of filtration without air lock.