Wedge-Shaped Filter Housing for Accurate Pleat Scaling
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Solution Overview
Problem
Current small-scale filtration tools inaccurately predict the performance of large-scale filtration devices due to flow restriction issues caused by high-density pleat configurations, leading to scaling inaccuracies from bench-top to production scales.
Innovation Solution
A scaling tool with a rigid wall framework that replicates the filtration performance of large-scale devices by fixing pleats in a specific orientation, allowing for proportional replication of filtration characteristics, including the use of a wedge-shaped filter receiving region defined by dimensions based on the large-scale device configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If high-density pleat configurations are used to increase membrane surface area in compact devices, then the membrane surface area to device volume ratio is improved, but flow restriction issues occur and filtration properties are affected
Solution Approach 1:
The patent changes the geometric parameters of the pleat structure by introducing a wedge-shaped filter receiving region with specific inclusion angles. This modifies the pleat compression distribution and inter-pleat angles, allowing high membrane surface area to be packed while maintaining adequate flow channels. The wedge shape creates a gradient in pleat density that balances surface area maximization with flow restriction mitigation.
2Area of moving object
If more pleats are inserted into a cylindrical cartridge to increase filtration area, then the membrane surface area is improved, but the angle between pleats decreases and compression increases, affecting filtration properties
Solution Approach 1:
The patent transitions from a symmetric cylindrical cartridge to an asymmetric wedge-shaped filter receiving region. This asymmetry allows the pleats to be arranged at optimized inclusion angles rather than being constrained by circular geometry. The wedge shape creates non-uniform pleat distribution that maintains consistent filtration properties across the membrane surface while achieving high packing density.
3Area of moving object
If the denser pleat structure is used to maximize membrane area, then the membrane surface area is improved, but it becomes more difficult for particles to migrate between pleats, causing scaling inaccuracy
Solution Approach 1:
The patent applies local quality by creating zones of different pleat densities within the wedge-shaped filter receiving region. The inclusion angle variation creates regions with different compression levels, allowing particles to access lower regions of the pleated membrane more effectively. This local variation in pleat structure maintains scaling prediction accuracy while maximizing overall membrane surface area.
Data Source
AI summary
A scaling tool for replicating filtration characteristics of a large-scale filtration device, the scaling tool comprising a housing having a fluid inlet and a fluid outlet, and a filter receiving region in fluid communication with the fluid inlet and the fluid outlet and configured to contain a membrane comprising one or more pleats, the filter receiving region being defined by a rigid wall framework configured to hold the one or more pleats of the membrane and compress the pleats in an amount effective to replicate the filtration performance of the large-scale filtration device. Also disclosed is a methodology for configuring a filter receiving region in a scaling tool.