Disc Filter Segment Injection Molding
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Solution Overview
Problem
Existing methods for producing disc filter frames are time-consuming and consume excessive filter material due to the need for pre-tensioning and gluing of filter materials, particularly in aluminum frames and prefabricated stainless steel or glass fiber frames.
Innovation Solution
A two-step injection molding process is used to create a disc-shaped filter segment where the filter material is integrated into the frame in a stretched condition, eliminating the need for subsequent mounting and gluing, and incorporating reinforcement beams for increased stability and load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter material is pre-tensioned and glued to the frame, then the filter material is securely mounted, but the process is time-consuming and consumes excessive filter material
Solution Approach 1:
The filter material mounting and frame formation operations are merged into a single injection molding process. The filter material is placed in the mold cavity before injection, and the molten plastic integrates with the material in one step, eliminating separate mounting and gluing operations.
Solution Approach 2:
The filter material is pre-positioned and pre-tensioned within the mold cavity before the injection molding process begins. This preliminary positioning ensures proper tension and alignment is achieved during the molding process itself, rather than requiring post-processing tensioning and mounting operations.
2Stability of the object's composition
If filter material is pre-tensioned with hanging weights, then the cloth is properly tensioned, but a large amount of filter material is consumed
Solution Approach 1:
The mechanical pre-tensioning system using hanging weights is replaced with a mold-based tensioning system. The mold cavity itself provides the tensioning force through its geometry and the injection pressure, eliminating the need for separate mechanical tensioning devices and reducing material consumption.
Solution Approach 2:
The tensioning mechanism changes from external mechanical weights to internal mold geometry and injection pressure parameters. By controlling the mold cavity shape and injection parameters, the desired tension is achieved without the material waste associated with traditional pre-tensioning methods.
3Stability of the object's composition
If the frame is made from prefabricated profiles joined together, then the frame structure is stable, but the construction process is time-consuming
Solution Approach 1:
The frame construction process is merged with filter material integration in a single injection molding operation. The frame and filter material are formed simultaneously as an integrated unit, eliminating separate assembly steps and significantly improving productivity while maintaining structural stability.
Solution Approach 2:
The frame is formed as a composite structure integrating plastic material with the filter material through injection molding. This composite approach creates a stable, integrated structure that combines the strength of the molded frame with the functional properties of the filter material in one manufacturing process.
4Productivity
If aluminum frame is used, then the number of working operations is reduced, but machining and gluing are still time-consuming
Solution Approach 1:
The mechanical machining and gluing operations are replaced with an injection molding process. The frame is formed directly through molding with the filter material integrated during the same process, eliminating post-molding machining and gluing operations that consume time despite using aluminum frames.
Solution Approach 2:
The frame formation and filter material attachment operations are merged into a single injection molding process. This integration eliminates the sequential machining and gluing steps that, while reduced in number with aluminum frames, still consume significant time in traditional manufacturing approaches.
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 enables mass production with fewer operations, reduces material consumption, and results in a filter frame with improved stability and reduced bulging under load, extending the working life of the filter material and allowing for shorter construction lengths.
Implementation Method 1
The filter frame is produced with the filter material (3) integrated therein by injection moulding in one and the same process
Data Source
Figure 1a~1b
Figure 2
AI summary
A method and device for making a disc shaped filter segment (1) of a disc filter (not shown), said filter segment (1) comprising a filter frame (2) and a filter material (3), said filter frame (2) being adapted for a filter support (not shown) of the disc filter. The method includes injection moulding of the filter frame (2) in a lower half (4a) and an upper half (4b) with a filter material (3) placed between the lower half (4a) and the upper half (4b), said filter material (3) being stretched and during the injection moulding in stretched condition integrated in the lower half (4a) and the upper half (4b) of the filter frame (2), and wherein the filter material (3) after injection moulding exhibits a residual stretching of the material. The device concerns an injection moulded filter frame (2) with a filter material (3) integrated in stretched condition between a lower half (4a) of the filter frame (2) and an upper half (4b) of the filter frame (2), said filter material (3) after injection moulding exhibiting a residual stretching of the material.