Universal Pleating Assembly for Filter Media Reuse
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing pleated filter media assemblies are costly and wasteful due to their non-standardized sizes and shapes, leading to material waste and environmental pollution, as they require custom frames for each filtration unit, making replacements expensive and inefficient.
Innovation Solution
A progressive pleat forming assembly comprising a male member with pleat ridges and a female member with pleat valleys, allowing any porous filter media sheet to be pleated and reused, with the pleated filter media sandwiched between the members, enabling easy installation and replacement within filtration units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom frames are manufactured for each filtration unit to accommodate pleated filter media, then the filter media can be properly encased and installed, but the cost increases and material waste occurs due to non-standardized sizes and shapes
Solution Approach 1:
The patent creates a universal frame assembly design with standardized dimensions and features that can accommodate different pleated filter media sizes. The frame includes a reusable pleating tool integrated into its structure, allowing the same frame assembly to be used across multiple filtration units and applications, eliminating the need for custom-made frames for each unit.
Solution Approach 2:
The frame assembly is divided into separable components including the frame body, the integrated pleating tool, and the filter media holder. This segmentation allows the pleating tool to be removed and reused for creating pleats in different filter media, while the frame itself serves as a universal mounting structure, reducing material waste through component reuse.
2Reliability
If custom frames are manufactured for each filtration unit, then proper fit and function are achieved, but the manufacturing cost increases
Solution Approach 1:
The frame assembly is designed as a universal component with standardized dimensions, mounting features, and an integrated pleating tool that can be used across multiple filtration units. This universality allows a single frame design to serve multiple purposes and applications, significantly reducing per-unit manufacturing costs while maintaining proper fit and function.
Solution Approach 2:
The pleating tool is merged with the frame assembly, creating an integrated unit where the tool becomes part of the frame structure. This combination eliminates the need for separate custom tooling for each frame, reducing manufacturing complexity and cost while ensuring the pleating function is properly integrated into the overall assembly.
3Reliability
If traditional filter encasement methods are used, then the filter media is protected, but replacement cost increases and environmental pollution occurs
Solution Approach 1:
The frame assembly is designed to be reusable and durable, allowing the same frame to be used multiple times across different filter media replacements. The integrated pleating tool can be removed and reused for creating pleats in new filter media, reducing the need to discard entire frame assemblies with each filter replacement and minimizing environmental pollution from wasted materials.
Solution Approach 2:
The universal frame design can accommodate different filter media sizes and types, allowing a single frame assembly to protect multiple different filters throughout its service life. This extends the useful life of each frame and reduces the total number of frames needed, thereby reducing material waste and environmental pollution.
Data Source
AI summary
An assembly for pleating a filter media sheet and using the assembly with a pleated filter media as a filter for filtration units. The assembly includes a male member and a female member. The male member includes several pleat ridges arranged in rows and columns and the female member includes several pleat valleys arranged in rows and columns. The filter media sheet can be placed over the female member and a last column of pleat ridges can be gently pressed over a first column of pleat valleys, such that the first column is within the last column, respectively. The step can be repeated incrementally till the last column of the pleat ridges is within the last column of the pleat valleys progressively forming a pleated filter media sandwiched between the male member and the female member.