A Digital Framework for Pleat Optimization

Computer-Aided-Design (CAD) is used by filter makers to speed up manufacturing of filters and filter elements. In this context, modelling pleats with multilayered materials and varying pleat counts can be so tedious that very few designs are manufactured and tested.

CAD data may also be used as input to simulations to predict the pressure drop, filter efficiency and filter lifetime. We present a simulation framework that starts with the CAD data but then permits automatic parameter studies on the pleats.  Compared to other methodologies, our 3d image-based approach works completely automatic and requires no manual meshing steps before the simulations can run.

As example, we simulate a filter with different pleat counts and volumetric flow rates to find the local minimum of the pressure drop. The approach finds the right balance for the pleat count between lowering the pressure drop by providing more filter area and raising the pressure drop through capillary forces in the inflow and outflow channels between the pleats. This allows to digitally test the performance of filter prototypes without relying on expensive production and testing phases. Only then promising prototypes undergo measurements on the real testbench. To further increase the productivity, the simulations can be run in the cloud. In this way, the parameter studies with varying geometries or flow rates can be run simultaneously and take only as long as a single simulation.