Embossed Fluid Filter Stability via Segmented Diagonal Support
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Solution Overview
Problem
Existing fluid filter elements with embossed fold walls face stability issues under fluctuating pressure loads and dust deposition, particularly in fluid-dynamic applications, due to rotation points and accordion effects that increase pressure drop and reduce aerodynamics.
Innovation Solution
A fluid filter element with embossed flat filter material featuring alternating first and second embossing rows, where at least one distal embossment is negative, and the application of adhesive to bond adjacent walls, eliminating rotation points and accordion effects by creating a diagonal support structure that resists bending and maintains aerodynamic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple embossings are laid against each other in fold walls, then the filter element structure is simple and easy to manufacture, but stability problems occur under fluctuating pressure loads and dust deposition
Solution Approach 1:
The embossing is divided into multiple segments: a first embossing portion extending from one side of the wall, a second embossing portion adjacent to the first and extending from the other side, and an intermediate embossing portion connecting them. This segmentation prevents rotation points while maintaining structural integrity and stability under pressure loads.
Solution Approach 2:
The embossing structure is extended into the third dimension by adding depth variations with the intermediate portion positioned at a different depth than the first and second portions. This creates a three-dimensional structure that eliminates rotation points and prevents accordion effects, improving stability without complicating the manufacturing process.
2Device complexity
If embossings are simply laid against each other without intermediate portions, then the filter element is simpler in structure, but rotation points and accordion effects increase pressure drop and reduce aerodynamic performance
Solution Approach 1:
The embossing is segmented into first, second, and intermediate portions that work together to eliminate rotation points. This segmentation creates a stable structure that prevents accordion effects, thereby reducing pressure drop and improving aerodynamic performance without excessive complexity.
Solution Approach 2:
The depth parameter of the embossing is varied along its length, with the intermediate embossing portion positioned at a different depth than the first and second portions. This parameter change creates a profile that eliminates rotation points and reduces harmful accordion effects, lowering pressure drop while maintaining reasonable structural complexity.
3Ease of manufacture
If constant height adhesive is used to connect adjacent embossings, then the adhesive application is simplified, but the embossings may not adequately resist bending forces under varying pressure conditions
Solution Approach 1:
The depth parameter of the embossing is varied to create first, second, and intermediate portions at different depths. This parameter change creates a more rigid structure that better resists bending forces under varying pressure conditions, while the adhesive connects these structured embossings to maintain overall stability.
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 solution enhances the stability and aerodynamic performance of the filter by eliminating rotation points and accordion effects, reducing pressure drop and maintaining flow characteristics under varying conditions.
Implementation Method 1
an adhesive connecting adjacent embossings of adjacent walls
Data Source
AI summary
A fluid filter element comprising: an embossed flat filter material which is folded so as to define a plurality of substantially adjacent walls, each wall defining a planar surface between two adjacent fold lines, said wall having an embossing comprising: a first embossing row having a centrally located elongated positive embossment and a distal embossment at each end of the positive elongated embossment, wherein at least one distal embossment is negative; and, a second embossing row spaced from and parallel to the first embossing row, the second embossing row having two elongated embossments, wherein one elongated embossment is negative and one is positive. A method regarding the making of the same.