Deformable Lug Overpressure Leak Detection

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Solution Overview

Problem

Existing water filter cartridges are prone to rupture or leakage due to high line pressures and water hammer, leading to damage and liability issues, with no reliable method to determine the source of failure between overpressure, water hammer, or defects in the filter.

Innovation Solution

The design incorporates a bayonet mount with a first permanently deformable portion and a second stop portion that maintain a watertight seal at higher test pressures, allowing for visual confirmation of deformation and limiting axial movement to prevent leakage, thus indicating if the failure was caused by exceeding the rated pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the filter cartridge is tested at high qualification pressures (300-500 psi) to ensure reliability, then the cartridge can withstand overpressure conditions, but the cartridge housing may rupture or leak during testing

Engineering Contradiction:

Improvecartridge pressure resistanceVSAvoidhousing strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The bayonet mount connector is divided into two distinct portions: a first permanently deformable portion and a second stop portion. This segmentation allows the deformable portion to yield at qualified pressures while the stop portion maintains structural integrity and prevents housing rupture during high-pressure testing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first permanently deformable portion acts as an intermediary element between the high test pressure and the cartridge housing. It absorbs the excessive pressure through controlled permanent deformation, protecting the housing from rupture while still allowing the cartridge to be tested at qualification pressures

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a single stop portion is used to prevent cartridge ejection, then axial movement is limited, but it is impossible to determine whether failure was caused by overpressure or water hammer

Engineering Contradiction:

Improvefailure source identificationVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The first permanently deformable portion changes its physical state from undeformed to permanently deformed, creating a visible indicator. This deformation serves as a visual signal (analogous to color change) that distinguishes overpressure failure from water hammer failure, enabling reliable failure source identification

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The connector transitions from a static single-stop design to a dynamic two-portion design where the first portion can deform under load. This dynamic response allows the system to differentiate between temporary pressure spikes (water hammer) and sustained overpressure conditions based on whether permanent deformation occurs

Inventive Principle:

Principle #15Dynamics

3Force

If the bayonet mount uses a rigid structure to resist ejection pressure, then the cartridge remains securely mounted, but the cartridge cannot accommodate pressure variations without risking rupture

Engineering Contradiction:

Improveejection pressure resistanceVSAvoidpressure damage

Core Design Contradiction:

ForceVSObject-affected harmful factors

Solution Approach 1:

The first permanently deformable portion is designed with specific material and geometric parameters that allow it to yield at pressures between the normal operating pressure (60 psi) and the qualification test pressure (300-500 psi). This parameter optimization enables the mount to resist normal ejection forces while accommodating pressure variations without causing housing rupture

Inventive Principle:

Principle #35Parameter changes

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 solution allows for objective evidence of pressure-related failures, protecting the cartridge manufacturer from liability and ensuring the filter can withstand qualification pressures without leaking, while allowing for testing at pressures greater than the rated operating pressure.

Implementation Method 1

a first deformable portion made of a material having a yield strength that deforms at an excessive line pressure

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

a first deformable portion made of a material having a yield strength that deforms at an excessive line pressure

Methodology Applied

Scientific EffectYield strength: Plasticity

Data Source

PatentUS11654382B2Overpressure leak detection lug

Publication Date: 2023.05.23 BAIRD MICHAEL T

AI summary

A filter cartridge with a longitudinal axis has mounting lugs engaging mating manifold flanges in an appliance to hold the cartridge in the appliance with fluid flowing through the cartridge at a line pressure of X psi while the lugs are designed for a greater, rated pressure Y. Each lug has a deformable portion and an aligned stop portion that are axially aligned. A distance d separates each stop portion from the axially aligned deformable portion. The deformable portion is below the stop portion and located to contact the manifold flange during use. The deformable portion permanently deforms above the rated pressure Y and below a qualification pressure Z that is at least twice the pressure X.