Co-moulded Fuel Injector Filter with Integrated Tubular Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter production methods for injectors and fluid systems require separate production and assembly of components, leading to increased costs and potential issues during assembly, with a complex overmoulding process that can result in component separation and impurity deposition.
Innovation Solution
A filter produced using co-moulding, where a tubular plastic element and a filter element are formed together in a single injection moulding operation, eliminating the need for separate components and ensuring the filter element is fully integrated and protected within the tubular structure, enhancing mechanical rigidity and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate production and assembly of filter components is used, then manufacturing flexibility is improved, but production costs increase and assembly complexity increases
Solution Approach 1:
The patent combines the filter element and support structure into a single integrated component produced by co-moulding. The support structure includes integrated attachment elements that directly connect to the filter element during the same manufacturing process, eliminating separate assembly steps and reducing overall device complexity while maintaining manufacturing flexibility.
Solution Approach 2:
The filter element is nested within the support structure during co-moulding, where the support structure is formed around the filter element in a single operation. This nesting approach allows the smaller filter element to be protected and secured by the larger support structure without requiring separate assembly operations.
2Strength
If overmoulding process is used to attach annular element to filter element, then mechanical strength is improved, but impurity deposition occurs and component separation issues arise
Solution Approach 1:
The patent uses co-moulding to create a single integrated piece where the support structure and filter element are formed simultaneously from the same material. This eliminates the interface between separate components that would otherwise accumulate impurities, while maintaining the mechanical strength benefits of integrated construction.
Solution Approach 2:
The patent addresses the impurity deposition issue by designing the integrated structure with smooth transitions and eliminated crevices where impurities could accumulate. The co-moulding process creates a unified surface that prevents impurity trapping, converting the potential harm of complex assembly into the benefit of a cleaner, more maintainable structure.
3Adaptability or versatility
If separate components with metal collar and sealing elements are used, then adaptability to different conduits is improved, but production cost increases
Solution Approach 1:
The patent integrates the sealing function directly into the co-moulded support structure through designed contact surfaces and geometric features. This eliminates the need for separate metal collars and sealing elements, reducing the number of components and production costs while maintaining the ability to adapt to different conduit configurations through the integrated design.
4Area of stationary object
If filter element projects from annular element, then filtering surface area is improved, but mechanical protection is reduced
Solution Approach 1:
The patent nests the filter element within the support structure during co-moulding, allowing the support structure to extend over and protect the filter element while maintaining the necessary filtering surface area. The integrated design provides mechanical protection without compromising the functional surface area needed for filtration.
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 approach reduces production costs, simplifies handling, and provides enhanced mechanical protection and secure attachment of the filter element, while maintaining optimal filtering surface area and preventing impurity deposition during manufacturing.
Implementation Method 1
A filter produced using co-moulding, where a tubular plastic element and a filter element are formed together in a single injection moulding operation
Data Source
AI summary
Method for producing a filter for injectors of fuel, oil, solutions, additives and fluids in general, for example for braking and transmission systems. The filter including an element of plastic material and having a tubular shape, open at opposite ends, internally hollow and having on one wall of its internal cavity a plurality of projections spaced apart from one another. These projections interacting with portions of a filter element of the pleated type associated with this tubular element and capable of filtering the fluid circulating through the tubular element. The filter element and the tubular element to form a single filter body by being co-moulded, the filter element being incorporated and completely positioned within the tubular element, but having portions of filter surface area free of this tubular element to allow passage and filtration of circulating fluid.