FILTER MODULE, FILTER MODULE SYSTEM, AND METHOD FOR BINDING PARTICLES OF A MATERIAL MIXTURE

Abstract

A filter module for binding particles from a particle-laden material mixture, in particular from an aerosol or from a particle-laden fluid, is provided. The approach of deforming an open-pored medium, in particular periodically, by means of a relative motion relative to a deformation unit and in this way producing a motion of the material mixture to be filtered through the open-pored medium is provided, whereby the material mixture is filtered by the open-pored medium. According to an embodiment, a cylindrical open-pored medium is introduced, together with a deformation unit, into a cylindrical housing and said open-pored medium can be deformed geometrically, in particular periodically, preferably at least along the cylinder axis of the housing and/or in the radial direction, by means of the deformation unit. According to an embodiment, a plurality of filter elements are arranged adjacent to each other with respect to the longitudinal extent thereof and are deformed with respect, to the longitudinal extent thereof periodically, preferably in an undulating manner, in particular substantially sinusoidally, wherein the deformation motions of the filter elements are phase-shifted with respect to each other.

Claims

1. A filter module having a substantially cylindrical housing, into which is introduced: a substantially cylindrically shaped cylindrical open-pored medium which is designed to hold a material mixture; at least one deformation unit, wherein the cylindrical open-pored medium is geometrically deformable by the at least one deformation unit at least along the cylinder axis of the substantially cylindrical housing or in the radial direction; and at least one inlet and at least one outlet for the material mixture.

2. The filter module according to claim 1, wherein the at least one deformation unit is movable relative to the housing and the cylindrical open-pored medium.

3. The filter module according to claim 2, wherein in a relative movement, the at least one deformation unit is at rest and the housing and the cyclindrical open-pored medium move or that the housing and the cylindrical open-pored medium are at rest and the at least one deformation unit moves.

4. The filter module according to claim 1, wherein the cylindrical open-pored medium forms at least two cylinder sectors.

5. The filter module according to claim 4, wherein adjacent cylinder sectors are sealed against each other with respect to the material mixture.

6. The filter module according to claim 1, wherein the at least one inlet and/or the at least one outlet is set in a cover of the housing, wherein the cover is able to be coupled to the at least one deformation unit.

7. The filter module according to claim 1, wherein the at least one deformation unit has a helical geometry which is configured to act in a deforming manner on the cylindrical open-pored medium and thereby move the material mixture through the medium, into the medium, and/or out of the medium.

8. The filter module according to claim 7, wherein the at least one deformation unit is a shaft, a screw, or a hose body, or the at least one deformation unit comprises at least one eccentric.

9. The filter module according to claim 1, wherein the cylindrical open-pored medium is at least one of elastic and compressible.

10. The filter module according to claim 1, wherein the in the cylindrical open-pored medium is a substrate or a gel.

11. A method for binding particles of a material mixture in at least one medium using a filter module according to claim 1, wherein at least the following steps occur: a. providing the material mixture at one of the inlets of the housing; b. drawing in the material mixture by means of the at least one deformation unit being moved relative to the housing and the medium; c. binding the particles in the medium; d. pumping out the material mixture at least partially freed of particles at one of the outlets; e. terminating or continuing with step f; f. replacing the medium with another medium; and g. continuing with step a.

12. A filter module system comprising at least two filter modules according to claim 1, wherein a first filter module and a second filter module in the at least two filter modules are connected in series such that one outlet of the first filter module is connected to an inlet of the second filter module in a releaseable, force-conveying,, and material mixture-conveying manner.

13. A method for binding particles of a material mixture in at least one medium using a filter module system according to claim 12, wherein at least the following steps occur: a. providing the material mixture at an inlet of the first filter module; b. pumping out the material mixture from the first filter module at the one outlet and drawing in the material mixture into the second filter module at the inlet by means of the at least one deformation unit or the covers of the first and second filter modules being jointly moved relative to the housing and the medium the respective filter module; c. binding the particles in the first and second filter modules in their respective medium; d. pumping out the material mixture at least partially freed of particles at an outlet of a last filter module; e. terminating or continuing with step f; f replacing the medium in at least one filter module with another medium; g. continuing with step a.

14. A filter module for binding particles from a particle-laden material mixture comprising: a plurality of filter elements, wherein each filter element is filled with an open-pored medium and surrounded by a wall impermeable to the material mixture and to the open-pored medium and having at least one inlet and at least one outlet for the material mixture, wherein the material mixture can flow through each filter element in the direction of its longitudinal extension from the at least one inlet to the at least one outlet, and a deformation unit, wherein the filter elements and the open-pored medium are deformable by the deformation unit, wherein the filter elements are arranged side by side with respect to their longitudinal extension, and wherein respectively adjacent filter elements are connected to each other along their respective facing walls running substantially parallel to their longitudinal extension, wherein the deformation unit is designed to deform the filter elements with respect to their longitudinal extension periodically, and wherein deformation motions of the filter elements are phase-shifted relative each other.

15. The filter module according to claim 14, wherein the deformation motions of the filter elements are phase-shifted relative each other such that a periodic deformation motion results on the adjacently arranged filter elements along a series of locations at the same height with respect to the longitudinal extension of the filter elements.

16. The filter module according to claim 14, wherein at least one inlet or at least one outlet on a surface of at least one filter element exhibits an elongated shape with a longitudinal or transverse extension in a direction between a direction running transverse to the longitudinal extension of the filter element and a wavefront propagation direction.

17. The filter module according to claim 14, wherein the filter module further comprises at least one securing device by means of which the parts of the walls of the filter elements in an area of the inlets of the filter elements are fixable with respect to at least one stationary point external of the filter module.

18. The filter module according to claim 14, wherein the deformation unit comprises a plurality of rollers with at least partially different diameters which are configured to roll along the filter elements along the longitudinal extension of said filter elements and thereby deform the filter elements to at least partially different degrees of deformation.

19. The filter module according to claim 18, wherein the plurality of rollers is arranged on a plurality of parallel axes.

20. The filter module according to claim 19, wherein a first axis and a second axis adjacent to said first axis are arranged parallel to one another, and that for a pair comprising a first roller arranged on the first axis and a second roller directly adjacent to the first roller and arranged on the second axis, the distance separating the two axes is less than the sum of a radius of the first roller and a radius of the second roller.

21. The filter module according to claim 14, wherein the plurality of filter elements is arranged in a hollow cylindrical shape.

22. The filter module according to claim 21, wherein the deformation unit has a hollow cylindrical shape, wherein the deformation unit contacts the plurality of filter elements on their inner or outer sides, and wherein the filter elements and the deformation unit are configured to rotate relative to one another.

23. The filter module according to claim 22, wherein the filter module has at least two filter elements arranged one behind the other with respect to their longitudinal extension, wherein a first number of filter elements are arranged side by side with respect to their longitudinal extension in an axial direction of the hollow cylindrical shape in which the filter elements are arranged and a second number of filter elements are arranged one behind the other with respect to their longitudinal extension in a circumferential direction of the hollow cylindrical shape, and that the at least two filter elements are connected together along the respective parts of their walls extending transversely to their longitudinal extension and facing one another.

24. The filter module according to claim 23, wherein the number of periods of a periodic deformation of the filter elements greater with respect to their longitudinal extension by way of the deformation unit during a rotation of the deformation unit relative to the filter elements, than the number of hollow cylindrical filter elements arranged one behind the other with respect to their longitudinal extension.

25. The filter module according to claim 18, wherein the deformation unit contacts an inner side of the plurality of filter elements and a central roller is arranged on an inner side of the deformation unit which is designed to frictionally press at least one roller on each respective axis outward to the filter elements.

26. The filter module according to claim 14, wherein the deformation unit is configured to deform at least one part of the walls of the filter elements running substantially parallel to the longitudinal extension of the filter elements along which two adjacent filter elements are connected together.

27. A method for binding particles from a particle-laden material mixture with a filter module according to claim 14, wherein the material mixture is provided at least at one inlet of at least one filter element of the filter module, the open-pored medium in the filter element is deformed by the deformation unit, the material mixture is drawn into the filter element at the inlet, the material mixture flows through the filter element substantially in the direction of its longitudinal extension from the inlet to an outlet, wherein particles from the material mixture are bound in the medium and the material mixture is at least partially freed of particles pumped out at the outlet.

Description

[0107] Further advantages, features and possible applications of the first and second design concept of the present invention will become apparent from the following exemplary description in conjunction with the figures. Shown are:

[0108] FIG. 1 an exemplary embodiment of a filter module according to the first design concept of the invention in a perspective partially cutaway view along with five sectional images A0 to A4 seen axially from above as a sectional image at various points through the cylindrical housing;

[0109] FIG. 2 an exemplary embodiment of the section in the main flow direction through the filter module according to FIG. 1 for a cylinder sector with open-pored medium movement patterns T0 to T4;

[0110] FIG. 3 a schematic, perspective progressive image of the pumping process for the cylinder sectors of a filter module according to FIG. 1;

[0111] FIG. 4 movement patterns T0 to T4 for a single cylinder sector in the filter module according to FIG. 1;

[0112] FIG. 5 a perspective view of a filter module according to the second design concept of the invention in five different deformation states over the course of the periodic undulating deformation motion;

[0113] FIG. 6 an exemplary embodiment of a deformation unit of a filter module according to the second design concept of the invention with a plurality of rollers arranged on parallel axes;

[0114] FIG. 7 a depiction of the force compensation in a filter module according to FIG. 5;

[0115] FIG. 8 an exemplary embodiment of a filter module according to the second design concept of the invention with respective hollow cylindrical filter elements and a deformation unit which rotate relative to each other;

[0116] FIG. 9 s depiction of the possible positions of the inlets and outlets of the filter elements in a filter module according to FIG. 5;

[0117] FIG. 10 a further exemplary embodiment of a filter module according to the second design concept of the invention, wherein the walls connecting the filter elements are deformed.

[0118] FIG. 1 shows the steps of a continuous material mixture conveying process in the exemplary embodiment of a filter module according to the first design concept of the invention.

[0119] A medium 2 (e.g. an open-pored sponge) divided into a plurality (n=6 here) of circular cylinder sectors 9 separated in gas-tight manner from one another transverse to the direction of flow is fixed in a fixed cylindrical housing 1 accommodating flow in the axial direction. Each of the circular cylindrical sectors 9 is to be successively deformed by a deformation unit 4, 6 in the manner shown by A0 to A4 in FIG. 1 and thus exert its own conveying action on the material mixture.

[0120] The inner sides of the circular cylinder sectors 9 rest on a flexible shell 3 which, in the exemplary embodiment in the form of a rotating helix, forces the sinusoidal geometric progressions as shown in FIG. 2. The drive of the helical rotation is the deformation unit 4, 6, here shaft 4, which rotates with two covers 5 relative to the housing at rotational speed n. The in inlet 7 and out outlet 8 are situated in the covers 5. They for example ensure intake and expulsion of the material mixture in the proper circulatory state.

[0121] On the shaft 4 is a plurality of preferably circular disc-shaped, phase-shifted and radially extending eccentrics 6 which are rotatably fixed to said shaft 4 axially adjacent one another and preferably without gaps. The deformation unit 4, 6 consisting of the shaft 4 and the eccentrics 6 thus approaches a helical geometry.

[0122] The generating of the helical rotation is shown in sectional views A0 to A4. Shown in each case here is the eccentric 6 of the deformation unit 4, 6 attached to the respective location on the shaft 4 corresponding to the locations indicated in the perspective representation of the cylinder. The more closely the helix is approximated by the plurality of eccentrics 6, the more continuous is the conveying effect of the material mixture and the binding of particles in the medium 2. The eccentrics 6 travel in the flexible shell 3 with little friction. To that end, a bearing, in particular a roller bearing, is preferably arranged between each eccentric 6 and the shell 3.

[0123] Considering only that circular cylinder sector 9 located on the far right in section A0 in sections A0 to A4 shown in FIG. 1, and theoretically supplementing with all the states of the medium 2 between depicted sections A0 to A4, results in images T0 to T4 from FIG. 2 in a tangential view from above.

[0124] The medium 2 preferentially has low material damping and high fatigue strength. An optional effect-enhancing fluid of the material mixture should thereby have a surface tension which does not unnecessarily inhibit the expanding of the medium 2.

[0125] FIG. 2 shows an example of the progression of the individual chronological geometric phases T0 to T4 of a subsection of the filter medium in section, wherein T4 again reaches position T0 after 360.

[0126] The transport process is similar to the pulmonary process with fine dusts. The essential difference is that in the filter module according to the invention, although a particle-laden material mixture, in particular an aerosol, is conducted through a medium 2 as in the lung, it is not intermittently bidirectional, as in a bellows pump, but rather continuously unidirectional. This is enabled by the medium being periodically compressed, preferably in sine waves, wherein the movement migrates in a conveying direction (see FIG. 2).

[0127] In FIG. 1, the in inlet 7 is closed at timepoint T0. The inlet 7 opens over timepoint T1 by the rotation of the cover 5 to the maximum in T2. As of that point, it closes again over T3 to T4, which corresponds to the initial position T0. During the conveying process, the sine crest migrates in the conveying direction, wherein the path for the material mixture in the respective circular cylinder sectors 9 is closed at both low points by the compressed medium 2. In the intermediate phases, backflow from the not yet completely closed media 2 of the respective circular cylindrical sectors 9 is prevented by the cover 5. The entrapped material mixture is thus driven by the tapering cross section as in the alveoli when exhaling. All non-adhering particles here must pass through the entire medium 2 on the way to the outlet 8.

[0128] The out outlet 8 is likewise closed in T0. It opens over timepoint T1 to the maximum in T2, whereby the filtered material mixture is expelled. As of that point, it closes again over T3 to T4 with further expulsion, which here as well corresponds to the initial position T0.

[0129] FIG. 3 depicts a schematic, perspective progressive image of the pumping or respectively transport process of a material mixture for the circular cylinder sectors. A full compensation of force takes place in the prior art filter module depicted in FIGS. 1 to 3, so that the constant pumping action is produced solely by drive torque through a single helical deformation unit. This ensues with a plurality of the filter elements (circular cylinder sectors) shown in FIG. 1, which are permeable only at the inlet and at the outlet and arranged such that their outer peripheral surfaces form a hollow cylinder shell. The walls of the filter elements are impervious to prevent transverse flows.

[0130] The disadvantage here is that the individual filter elements are not only deformed in a single direction transverse to the conveying flow, but in two.

[0131] FIG. 4 shows movement patterns T0 to T4 for a single cylinder sector in the prior art filter module according to FIG. 1. It can be seen that two points of the cross section in the shape of a layer cake slice describe a circular path, whereby there is unnecessarily high flexure and thus a shorter service life as well as higher energy consumption to be expected.

[0132] FIG. 5 shows a perspective view of a filter module 10 according to the second design concept of the invention in five different states of deformation over the course of the periodic undulating deformation motion.

[0133] A constant pumping effect is thereby achieved by a plurality of filter elements 11 being arranged side by side and constantly being deformed out of phase with each other. It can be seen that sinewave forms not only result in the conveying direction but also transverse thereto. Taken as a whole, the sinusoidal wavefronts migrate diagonal to the conveying direction. Using a plurality of adjacent filter elements 11 is required so that no flow occurs transverse to the conveying direction. A particularly uniform pumping effect is to be expected with purely sinusoidal waves.

[0134] FIG. 6 shows (FIG. 6a in a vertical cross section through filter module 10 and FIG. 6b in a plan view of or respectively in a section through the deformation unit) how the sine fronts can be e.g. mechanically generated: To achieve the closest possible desired deformation, rollers 13 arranged on axes 14 disposed at low axial spacing from one another roll along the filter elements 11 in the conveying direction. The rollers 13 have different diameters so that they form the sine fronts on the contact surfaces to the filter elements 11 and run at individual speeds with little friction. The axes 14 with the rollers 13 can intermingle via a ribbed break in the contour and thus be arranged at the smallest possible axial spacing.

[0135] It is also possible for the diameter of a roller 13 to change along the axial extension of the roller 13 and the roller 13 be correspondingly longer. This is particularly useful in the small diameter range in which it is not necessary for the rollers 13 of adjacent axes 14 to intermingle. Such a roller 13 can in particular assume an at least partially substantially conical (roller 13a ) or double-conical (roller 13b ) form.

[0136] The filter elements 11 should have the length of a sine wave for pulsation-free conveyance.

[0137] Since the rollers 13 would shear the filter element 11 trapezoidally in the conveying direction, a rocker 15 is mounted on the in inlet side which holds the wall of the filter element 11 in position.

[0138] Vertically acting actuators distributed for example over the surface can also produce the deformations per any given drive principle. In this case, no rocker 15 would be required.

[0139] The axes 14 with the rollers 13 shown in FIG. 6 are subjected to load with each respective sinusoidal segment and loaded with tilting torque in the asymmetrical case. Furthermore, there is always a load transverse the conveying direction as the rollers 13 run obliquely to the wavefronts.

[0140] FIG. 7 shows how these two unwanted loads respectively compensate each other by the symmetrical arrangement of multiple filter elements 11 in a filter module 10: The force arrows for the radial loads F.sub.r depicted at the front corners have the same lever arm to the center, which cancels the tilting torques, and the roller axial loads F.sub.a have opposite orientations. The wavefronts are illustrated by dashed/dotted lines and resemble a herringbone gearing pointing in the direction of conveyance.

[0141] Expedient with respect to the orientation of the wavefronts is the following flexible design to the tight walls 12 of the filter elements 11, corresponding to a bamboo roller blind: [0142] High flexural rigidity should prevail parallel to the dashed/dotted lines, produced for example by rod-shaped inserts, so as to approximate as close as possible the straight fronts also between adjacent rollers 13. [0143] High flexural elasticity should prevail transverse thereto so as to approximate as close as possible the sinusoidal shape. [0144] The elongating of the wall 12 produced by the greater path length of the sine waves relative to the filter elements 11 can be compensated by pretensioning or folding in the undeformed state. [0145] To avoid transverse thrust in the filter elements 11, their walls 12 are coupled to the environment, see the rocker 15 fixed at the in inlet in FIG. 6.

[0146] The force arrows for the radial loads F.sub.r incorporated into FIG. 7 have the same orientation and are thus cumulative.

[0147] FIG. 8 therefore shows an implementation of a filter module 10 according to the second design concept of the invention in which such compensation is realized by the uniform arrangement of at least two of the arrangements of filter elements 11 on a hollow cylinder shown in FIG. 7. For the purpose of pulsation-free conveyance in/out of inlets and outlets in1 to out3, at least one set more of axes 14 of a sine wave length than filter elements 11 should be used.

[0148] Here, however, the conveyance is tangential, as can be seen at the three marked locations in1 to out3, and not axial as in the prior art filter module. To homogenize the roll-over process, the walls 12 of the arrangements of filter elements 11 are coupled to the inlets and outlets in1 to out3.

[0149] Three arrangements of filter elements 11 and four sets of axes 14 are arranged in FIG. 8a such that all the deforming rollers 13 are pressed by a central roller 16. The drive at rotational speed n can directly ensue frictionally via the central roller 16 or positively via the axes 14 of the deforming rollers 13.

[0150] In FIG. 8b, the central roller 16 is replaced by the constant acting and same resultant forces F.sub.res1 to F.sub.res3 exerted by same on the arrangement of filter elements 11 and the drive torque T required to produce rotational speed n. It can be seen here that the force lines of action meet at one point and thus compensate.

[0151] This arrangement prevents the circular motions shown in FIG. 4: The filter medium 2 is in particular radially deformed and receives a minimal deformation component in the conveying direction, which is minimized with the length of the rocker 15. The arrangements of filter elements 11 can be connected hydraulically in series or in parallel and also contain different filter media, e.g. for the cascading of coarse to medium to fine filter media.

[0152] To take into account for smooth running of the arrangement from FIG. 8 is that the inlet and outlet surfaces of the arrangements of filter elements 11 should not be orthogonal to the flow direction since the impact of the rollers 13 generate mechanical shocks (see the sectional area marked M in FIG. 9). The oblique line marked H in the same place is likewise unsuited as the position of the inlet and outlet surfaces since maximum hydraulic pulsations occur in this case. An exemplary compromise is illustrated as sectional area marked L, the selection of which is expected to result in only slight mechanical and hydraulic irregularities.

[0153] FIG. 10 shows a further implementation of a filter module 10 according to the second design concept of the invention, wherein the deformation unit in this implementation deforms the walls connecting the filter elements.

[0154] Three adjacently arranged and connected filter elements 11 are depicted in FIG. 10. The arrows marked Q indicate the direction of flow of the material mixture to be filtered through the filter elements 10, wherein the inlet side is located on the left in the figure and the outlet side on the right.

[0155] The deformation unit comprises a series of spindle drives 18 with contact elements 17 configured as nuts which are connected at their outer surfaces to the walls 12 of the filter elements 11. The contact elements 17 are preferably bonded or welded to the walls 12 and/or positively connected to the walls 12 by a flat projection (not shown) being inserted at the respective contact element between two interconnected walls 12 of adjacent filter elements 11.

[0156] Each spindle drive 18 exhibits alternating sections of left and right threads which engage with corresponding left/right threads of the contact elements 17 such that adjacent contact elements 17 move in opposite directions upon a rotation of the spindle drive 18.

[0157] The spindle drives 18 are preferably arranged substantially parallel and equidistant from one another substantially perpendicular to the longitudinal extension of the filter elements 11 and over the entire longitudinal extension of the filter elements 11. Only three spindle drives 18 are depicted in FIG. 10 while the positions of the contact elements of the other (not shown) spindle drives are indicated by circles.

[0158] Each spindle drive 18 is connected at one end to the shaft of a motor 19 and can be rotated by same in both directions. By appropriately controlling the motors 19, the respective contact elements 17, which contact the same two connected walls 12 of adjacent filter elements 11, can be set into an undulating, preferably sinusoidal movement. The desired periodic deformation motions of the filter elements 11 are generated by the contact elements 17 exerting a corresponding pressure or tension on the walls 12.

[0159] In FIG. 10, the outer walls of the outward filter elements 11 are not deformed. Of course, however, further contact elements 17 connected to said outer walls can be provided on the spindle drives 18 in order to deform them in a periodic manner.

[0160] Due to the respective opposite movements of the adjacent contact elements 17 on the spindle drives 18, the movements of adjacent filter elements 11 in FIG. 10 are out of phase with each other. The phase offset thereby amounts to 180 degrees; i.e. while one filter element 11 is compressed, the adjacent or the two adjacent filter elements 11 is/are expanded and vice versa.

[0161] Values other than 180 degrees can be achieved for the phase offset by way of a (not shown) mechanism with which adjacent contact elements 17 can be moved independently of one another. To that end, each spindle drive 18 is preferably provided with a continuous thread of the same orientation (left or right thread) and the spindle drives 18 are not rotatably mounted. In contrast, each contact element 17 comprises a nut movable relative to the housing of the contact element 17 which engages with the spindle drive 18. In addition, each contact element 17 is provided with its own drive for rotating the nut, whereby the contact element 17 moves on the spindle drive 18. With appropriate control, which preferably ensues wirelessly, all the contact elements 17 can then move independently of each other on the spindle drives 18, whereby any given phase-shifted deformation motions can be realized.

[0162] In the implementation of the invention according to FIG. 10, the deformation motions act on the filter elements 11 in that direction in which the filter elements 11 are arranged side by side. The filter elements 11 therefore do not need any deflection space perpendicular to that direction during their deformation. This yields the advantage of almost completely filling the available space.

[0163] 3o Furthermore, several layers of adjacently arranged and connected filter elements 11 can be stacked one atop the other, whereby only the spindle drives 18 need to be led through in between the layers. In this case as well, the available space is almost completely filled.

LIST OF REFERENCE NUMERALS

[0164] 1 housing [0165] 2 medium [0166] 3 shell [0167] 4 shaft [0168] 5 cover [0169] 6 eccentric [0170] 7 inlet [0171] 8 outlet [0172] 9 circular cylinder sector [0173] T0-T4 timepoints (T4=TO) [0174] A0-A4 axial positions (A4=A0) [0175] n rotational speed [0176] 10 filter module [0177] 11 filter element [0178] 12 wall [0179] 13 roller [0180] 13a conical roller [0181] 13b double-conical roller [0182] 14 axis [0183] 15 rocker [0184] 16 central roller [0185] 17 contact element [0186] 18 spindle drive [0187] 19 motor