Polymeric Coated Filter Media Pack for Leak-Resistant Sealing
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Solution Overview
Problem
Conventional filter media packs are prone to puncturing and gouging during handling, lack strong bonding surfaces for seal members or mounting frames, and create leak paths due to difficult wrapping, which conventional wraps like polyester non-wovens and paper fail to address effectively.
Innovation Solution
A polymeric coating is applied to the outer surface of the filter media pack, providing a rough, hard, and penetrative layer that enhances puncture and crush resistance, offers a bonding surface for gaskets, and seals potential leak paths, while being applied via spraying or rolling without molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wraps (polyester non-wovens or paper) are used to protect filter media packs, then some reinforcement is provided, but the filter media remains vulnerable to puncturing and gouging during handling
Solution Approach 1:
The patent applies a polymeric coating material that combines the properties of flexibility and high strength. This coating forms a composite structure with the filter media pack, creating a protective outer layer that resists puncturing and gouging while maintaining the flexibility needed for handling and installation.
Solution Approach 2:
The polymeric coating changes the surface properties of the filter media pack by providing a harder, more resistant outer layer. This parameter change in surface hardness and strength protects against mechanical damage during handling without significantly altering the overall flexibility of the filter media pack.
2Strength
If conventional wraps are used to protect filter media packs, then some protection is provided, but strong bonding surfaces for attaching seal members or mounting frames are not achieved
Solution Approach 1:
The polymeric coating provides localized bonding strength at the surfaces where seal members or mounting frames need to be attached. The coating creates a specific bonding interface with enhanced adhesion properties, while the rest of the filter media pack maintains its original characteristics.
3Reliability
If conventional wraps are used to protect filter media packs, then some reinforcement is provided, but leak paths occur due to difficult binding to the filter media
Solution Approach 1:
The polymeric coating merges the protective function with the bonding function by forming an integral layer on the filter media pack surface. This unified structure eliminates the interface between separate wrap and media, preventing leak paths while simplifying the manufacturing process.
Solution Approach 2:
The polymeric coating forms a flexible thin film that conforms to the filter media pack surface, providing continuous coverage and sealing. This thin protective layer prevents leak paths while maintaining the flexibility needed for proper binding and installation.
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 polymeric coating stabilizes the filter media pack's dimensions, improves handling resistance, and prevents leaks by integrating with the filter media, offering a durable and aesthetically pleasing solution.
Implementation Method 1
The polymeric coating preferably penetrates the filter media pack to a depth of at least 9,000 μin.
Implementation Method 2
The polymeric coating can be a spray coating layer.
Implementation Method 3
The polymeric coating can have a surface roughness of at least 50 μin.
Data Source
AI summary
A filter element is provided. The filter element includes a filter media pack including an outer surface. The outer surface extending between a first flow face and a second flow face. The filter element also includes a polymeric coating applied to the outer surface of the filter media pack, wherein the polymeric coating is not a molded structure. In embodiments, the polymeric coating covers at least 25% of a span between the first flow face and the second flow face and has an average thickness of between 0.005 and 0.100 in. In other embodiments, the polymeric coating has a surface roughness of at least 50 μin to provide an outer gripping surface. A method and system for applying the polymeric coating to the filter element are also provided.