Multi-Media Filter Assembly with Staggered Pleat Geometry
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Solution Overview
Problem
Existing filter assemblies, such as HEPA filters, face challenges in maintaining performance and extending life due to increasing differential pressure as pores become clogged, leading to reduced airflow and limited effectiveness in reducing differential pressure.
Innovation Solution
A filter assembly is designed with multiple filter media bent in specific stages and shapes, where high-point and low-point portions are alternately formed to create a predetermined gap, allowing for uniform fluid distribution and reduced pressure, with frames to maintain alignment and rigidity, and an adhesive member to secure the bent shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media is bent in multiple stages to increase filter area, then filtration performance is improved, but differential pressure increases rapidly
Solution Approach 1:
The filter assembly is divided into multiple filter media layers (first filter medium, second filter medium) with different filtration rates. Each layer segments the filtration function, allowing particles to be captured at different stages rather than all at once in a single layer, thereby distributing the pressure drop across multiple interfaces and reducing rapid differential pressure increase.
Solution Approach 2:
Different filter media are positioned at different locations within the assembly. The first filter medium with higher filtration rate is placed at one position while the second filter medium with lower filtration rate is placed at another position. This local differentiation allows optimization of filtration performance in different regions while managing pressure distribution throughout the assembly.
2Device complexity
If single filter medium is used, then device complexity is reduced, but differential pressure cannot be reduced
Solution Approach 1:
Multiple filter media with different filtration rates are merged into a single filter assembly structure. The first filter medium and second filter medium are combined within the same frame system, creating a composite filtration system that achieves differential pressure reduction while maintaining relatively simple overall structure through integrated design.
3Reliability
If multiple HEPA filters with different filtration rates are combined, then filtration performance is improved, but differential pressure reduction effect is limited
Solution Approach 1:
The filter media are arranged in a nested configuration where the first filter medium and second filter medium are positioned within the same filter assembly, with one filter medium effectively nested within the spatial envelope of the other. This nested arrangement optimizes the flow path and particle capture efficiency, enhancing differential pressure reduction beyond simple side-by-side placement.
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 effectively reduces differential pressure, enhancing filtration performance and extending the filter's life by ensuring uniform fluid flow and maintaining structural integrity, while allowing for selective replacement of filter media to improve user convenience and economic efficiency.
Implementation Method 1
a first filter medium (110) that is bent so that high-point portions (111) and low-point portions (113) defined based on a vertical plane with respect to a first direction are alternately and repeatedly formed in a second direction perpendicular to the first direction
Data Source
AI summary
A filter assembly including: a first filter medium that is bent so that high-point portions and low-point portions defined based on a vertical plane with respect to a first direction are alternately and repeatedly formed in a second direction perpendicular to the first direction; a first filter frame configured to accommodate the first filter medium and to fix an edge side of the first filter medium; a second filter medium that is bent so that the low-point portions and the high-point portions based on the vertical plane with respect to the first direction are alternately and repeatedly formed in the second direction; and a second filter frame configured to accommodate the second filter medium and to fix an edge side of the second filter medium, wherein at least a portion of the high-point portions repeatedly formed in the first filter medium have different heights from those of the other high-point portions, and at least a portion of the low-point portions repeatedly formed in the second filter medium have different heights from those of the other low-point portions, and the first and second filter media are bent in such a way that a first filter medium high-point envelope connecting high points of the first filter medium and a second filter medium low-point envelope connecting low points of the second filter medium correspond to each other when viewed from a cross-section including the first direction and the second direction, and the first and second filter frames are combined with each other so that the first filter medium high-point envelope and the second filter medium low-point envelope face each other.