Regenerable Filter Element with Loose Balls and Support Layers
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Solution Overview
Problem
Existing filter elements are not reliably backwashable, often clog, and lack a sharp and reproducible separation limit, making them unsuitable for fine and ultra-fine filtration, especially in applications like food technology where they can be damaged by backflushing and have high production costs due to connected balls.
Innovation Solution
A regenerable filter element with loosely arranged balls between permeable support layers, which are held in place by clamping elements, allowing for backwashing and regeneration without damaging the filter, and enabling precise filtration by using calibrated balls and additional protective layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If balls are connected together (glued or sintered) to form a filter layer, then the filter element has structural stability, but the manufacturing cost increases and the filter cannot be reliably backwashed
Solution Approach 1:
The filter element is segmented into distinct functional layers: a support layer, a filter layer with loose balls, and a protective outer layer. This segmentation allows the balls to remain loose and backwashable while the support layer provides structural stability, resolving the contradiction between backwashability and structural integrity.
Solution Approach 2:
The support layer acts as an intermediary between the loose balls and the external environment. It provides the necessary structural stability and containment for the loose balls, enabling reliable backwashing without requiring the balls to be connected together, thus reducing manufacturing cost while maintaining reliability.
2Stability of the object's composition
If balls are connected together to form a filter layer, then the filter structure is stable, but the filter element becomes complex and expensive to produce
Solution Approach 1:
The filter element is divided into functional segments: a stable support layer that provides structural integrity and a loose filter layer with balls that enables simple backwashing. This segmentation achieves filter layer stability without complex ball connections, reducing production complexity.
Solution Approach 2:
The support layer is designed as a simple, inexpensive structural component that can be easily manufactured and replaced if needed. This allows the use of loose, simple balls in the filter layer without requiring complex connection mechanisms, reducing both device complexity and production costs.
3Productivity
If high pressure backflushing is applied to clean fine filters, then the filters can be regenerated, but the filter balls are damaged
Solution Approach 1:
The protective outer layer serves as a cushion that absorbs and distributes the mechanical stress during backflushing operations. This beforehand cushioning protects the filter balls from direct high-pressure impact, enabling regeneration capability while maintaining ball integrity.
Solution Approach 2:
The protective outer layer acts as a flexible shell that can deform under pressure to distribute stress evenly across the filter balls. This flexibility allows high-pressure backflushing for regeneration while preventing localized stress concentrations that would damage the balls.
4Ease of manufacture
If loose balls are used in the filter layer, then the filter element is cost-effective and suitable for food technology, but the balls may move or detach during operation
Solution Approach 1:
The filter element is segmented into a support layer that provides structural stability and a filter layer with loose balls. This segmentation keeps production costs low while the support layer ensures ball position stability during operation, preventing detachment.
Solution Approach 2:
The support layer acts as an intermediary that anchors the loose balls in place during normal operation. This intermediary structure maintains ball position stability without requiring the balls to be connected, keeping production costs low and the filter suitable for food technology applications.
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 element achieves sharp and reproducible separation limits, is cost-effective, and can be used for coarse, fine, and ultra-fine filtration without damaging the balls, allowing for efficient backflushing and regeneration, suitable for sensitive fluids like those in food technology.
Implementation Method 1
the supporting layers hold the otherwise loose balls of the filter layer in their respective positions, so that they remain immovably arranged even when the filter element is in operation
Implementation Method 2
a filter layer formed from balls, which is arranged between a permeable inner support layer adjoining the filter layer and a permeable outer support layer adjoining the filter layer
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The element (10) has a filter layer (12) formed from balls (14) and arranged between inner and outer supporting layers (18, 20). The supporting layers comprise a separation limit that is smaller than diameter of the balls. The balls are arranged in the filter layer in a detachable manner, and an elastically designed clamping element (32) is arranged on an outer side of the outer supporting layer and clamps the outer supporting layer against the filter layer. The supporting layers are made from fabric layers, and the clamping element is formed by radial spring rings.