Air Filter End Plate Thermal Welding Seal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air filter elements for internal combustion engines and ventilation systems face challenges in achieving a reliable and cost-effective seal, particularly under mechanical and thermal loads, due to the connection between the end plate and filter body being prone to leaks.
Innovation Solution
The end plate is produced as a separate component and firmly connected to both end plates and the filter body using a thermal process, where the end plate connection areas are fused to the end plates and the filter body, ensuring a tight and reliable seal by melting and plasticizing the materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end plate is glued or clipped to the end plates and filter body, then the production process is simple, but the seal reliability deteriorates under mechanical and thermal loads
Solution Approach 1:
The patent replaces mechanical connection methods (gluing, clipping, foaming) with a thermal welding process. The end plate is heated to its melting point and fused directly to the end plates and filter body, creating a monolithic structure that maintains seal integrity under mechanical vibrations and thermal loads while remaining suitable for series production.
Solution Approach 2:
The invention utilizes the phase transition of the end plate material from solid to liquid state through heating. The end plate connection areas are heated until they melt and fuse with the end plates and filter body, then cool to form a permanent, leak-proof bond that withstands operational stresses.
2Reliability
If a thermal process is used to fuse the end plate, then the seal reliability improves, but the production complexity increases
Solution Approach 1:
The thermal welding process is segmented into distinct zones: end plate connection areas on the end plate, corresponding connection areas on the end plates, and end fold connection areas on the filter body. This segmentation allows localized heating and welding without requiring complex equipment, as each zone can be addressed independently during the welding process.
Solution Approach 2:
The end plate material itself serves as the welding material. By heating the end plate connection areas to their melting point, the material becomes self-adhesive and fuses with the end plates and filter body without requiring additional adhesives, sealants, or complex welding consumables, simplifying the overall production process.
3Adaptability or versatility
If the end plate is produced as a separate component, then the adaptability improves, but the manufacturing steps increase
Solution Approach 1:
The separate end plate, end plates, and filter body are merged into a single monolithic structure through thermal welding. The end plate connection areas and end fold connection areas are fused with the respective components during assembly, eliminating the need for separate sealing operations and creating an integrated structure that maintains design flexibility while improving production efficiency.
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
This method provides a high degree of reliability and simplicity in production, effectively preventing leakage flows and ensuring the integrity of the seal even under mechanical and thermal stress, making it suitable for series production.
Implementation Method 1
the end plate connection areas and the front ends are heated and, in particular, melted until sufficient plasticization is achieved
Implementation Method 2
the end plate connection areas and the front ends are heated and, in particular, melted until sufficient plasticization is achieved
Implementation Method 3
melted until sufficient plasticization is achieved that, when the front plate is pressed against the end plates, the desired materially bonded fusion or melted connection
Implementation Method 4
the end fold connection areas of the face plate are heated and, in particular, melted until sufficient plasticization occurs
Implementation Method 5
heated and, in particular, melted until sufficient plasticization occurs
Implementation Method 6
sufficient plasticization occurs. The filter body can then be pressed with its respective end against the respective end fold connection area
Data Source
AI summary
The invention relates to a filter element, in particular an air filter element (1), for a fresh air system of an internal combustion engine, or for a ventilation- and/or air-conditioning device of a motor vehicle, said filter element comprising: a filter body (2) made of a folded filter material (6), that laterally surrounds an internal space (7) of the filter element (1), except in a lateral connection region (8); a first end plate (3) and a second end plate (4) which are sealingly attached to the filter body (2) at sides that are facing away from one another; and a front plate (5) which is arranged in the connection region (8) and which has a connecting piece (13) for supplying or conducting away air. A reliable construction is formed when the front plate (5) has first and second end plate joining regions (14, 16) facing the first and second end plates (3, 4), which end plate joining regions are fused with the front-side front plate (5)-facing ends (15, 17) of each end plate (3, 4), and when the front plate (5) has first or second end fold joining regions (18, 19) assigned to a first or second end (9, 10) of the filter body (2), into which end fold joining regions at least one first or second end fold (11, 12) is plasticised, said end fold being formed at the first or second end (9, 10) of the filter body (2)