Additive Manufactured Filter Element with Integrated Surface Layer
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Solution Overview
Problem
Conventional filter elements for gas streams are limited by the sintering process, which restricts the use of plastics and filter body structure, requiring multiple pieces to be joined together, and lacks flexibility in geometry and material composition.
Innovation Solution
A throughflow-porous filter element with a three-dimensional support structure manufactured via additive manufacturing, allowing for a single-piece construction with a surface filtration layer integrated into the cavities, enabling precise geometry and mechanical properties without the need for molds, and providing a durable bond under heavy loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sintering process is used to manufacture filter bodies, then inherently stable filter elements can be produced in large numbers, but the process is limited in the plastics that can be used and the structure of filter body and surface filtration layer
Solution Approach 1:
The patent changes the manufacturing process parameters from conventional sintering to additive manufacturing, enabling the use of diverse plastics and complex structures while maintaining production efficiency. The additive manufacturing process allows for variable material properties and geometric configurations that were not achievable with traditional sintering methods.
Solution Approach 2:
The filter element combines a filter body made from one or more plastics with a surface filtration layer, creating a composite structure that leverages the advantages of different materials. The additive manufacturing process enables precise integration of multiple materials with different properties within a single manufactured part.
2Ease of manufacture
If multiple pieces are joined together to form filter bodies, then the filter element can be manufactured, but the construction is more complex and less stable
Solution Approach 1:
The additive manufacturing process merges multiple components into a single integrated filter body structure. The filter body, support structures, and surface filtration layer integration are achieved in one manufacturing operation, eliminating the need for separate assembly steps and reducing structural complexity.
Solution Approach 2:
The filter body incorporates integrated support structures and cavities that are segmented into functional zones but manufactured as a single piece. This segmentation is achieved through digital design and additive manufacturing, allowing complex internal geometries without requiring physical assembly of multiple parts.
3Manufacturing precision
If conventional manufacturing processes are used, then standard geometries can be produced, but complex geometries and varied materials cannot be realized
Solution Approach 1:
The patent utilizes additive manufacturing technology which fundamentally changes the manufacturing parameters from mold-based to digital-file-based production. This enables arbitrary geometric configurations and material compositions to be directly translated from digital models into physical filter elements with high precision, without the constraints of conventional mold geometry.
4Ease of manufacture
If surface filtration layer is applied as spray coating, then filtration function is provided, but the bond durability under heavy loads is insufficient
Solution Approach 1:
The additive manufacturing process merges the filter body and surface filtration layer into a single integrated structure. The surface filtration layer is built up layer-by-layer directly on the filter body during the same manufacturing process, creating inherent mechanical interlocking and strong adhesion that cannot be achieved through post-application spray coating methods.
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 solution allows for the production of filter elements with complex geometries and varied materials, enhancing stability and filtration efficiency while reducing manufacturing steps and costs, and enabling effective retention and cleaning of foreign substances.
Implementation Method 1
a three-dimensional support structure manufactured in an additive manufacturing process
Implementation Method 2
a surface filtration layer which is formed on the inflow side of the filter body... for filtering foreign substances from a gas stream
Data Source
AI summary
An inherently stable, throughflow-porous filter element for filtering foreign substances from a gas stream, comprising a filter body of plastic and having an inflow side and an opposite outflow side, wherein a surface filtration layer is formed on the inflow side, wherein the filter body has a three-dimensional support structure manufactured in an additive manufacturing process, said support structure having cavities through which gas can flow from the inflow side to the outflow side, and wherein the surface filtration layer at least partially fills the cavities of the three-dimensional support structure.