Star-Pleated Filter Cartridge for Water Separation Without a Center Tube
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Solution Overview
Problem
Conventional filter cartridges with pleated media have limitations in maximizing filter media usage and water separation efficiency, often requiring a center tube that increases manufacturing costs and complicates assembly.
Innovation Solution
A filter cartridge design featuring star pleating geometry with variable radial heights and sealed pleats, eliminating the center tube, and incorporating embossments for structural strength, which enhances water separation and simplifies assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional pleated filter media are used, then filter media usage is increased, but water separation efficiency is limited and center tube is required
Solution Approach 1:
The filter media is divided into multiple pleats of varying heights (first pleats, second pleats, third pleats) arranged in segments around the filter element. This segmentation allows different regions to perform different functions: deeper pleats provide more surface area for water separation while shallower pleats maintain structural integrity, eliminating the need for a center tube.
Solution Approach 2:
Different portions of the filter media have different pleat heights and properties. The first pleats have greater radial height than second pleats, which have greater height than third pleats. This local variation in quality optimizes water separation efficiency in regions where it is most needed while maintaining overall structural stability.
2Strength
If center tube is used in conventional filter cartridges, then structural integrity is maintained, but manufacturing cost increases and assembly becomes complicated
Solution Approach 1:
The center tube is completely removed from the filter element design. Instead of relying on a central structural support, the invention uses the outer pleats (particularly the first pleats with greatest radial height) to provide structural integrity and support for the filter element, simplifying both manufacturing and assembly.
Solution Approach 2:
The structural support function previously performed by the center tube is merged with the filter media itself. The pleats, particularly the deeper first pleats, simultaneously provide filtration surface area and structural support, eliminating the need for separate central support components.
3Ease of manufacture
If uniform pleat heights are used, then manufacturing is simplified, but filter media surface area is not maximized
Solution Approach 1:
The filter media incorporates pleats of varying heights at different locations around the filter element. The first pleats have greater radial height than second pleats, which have greater height than third pleats. This local variation maximizes the total surface area available for filtration and water separation while remaining manufacturable through controlled pleating processes.
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 design improves water separation performance and reduces manufacturing costs by utilizing a streamlined fluid flow path and eliminating the center tube, while maintaining structural integrity.
Implementation Method 1
As the fluid passes through the filter material, a sufficient amount of the contaminants will be captured by the filter material
Implementation Method 2
The separated water then drains down into the collection bowl
Data Source
AI summary
A filter cartridge includes an open-ended housing and filter element supported in the housing and defining an annular region between a periphery of the filter element and a side housing wall. A water collection region is between an end of the filter element and a lower-housing wall. The filter element includes pleated media surrounding an axially-extending central area, and pleats of different heights round the central area. An end plate is bonded to the filter element to prevent fluid flow through the pleats' upper ends. One passage is through a plate opening into the central area. Another passage is between the end plate and peripheral region. The filter element has freely-supported lower ends. A seal between the lower periphery of the filter element and the housing prevents fluid bypass of the filter element. Fluid passes through the pleats, and water coalesces on the media and drains into the collection region.