Extruded Polymer Seal for Filter Element Moisture Resistance
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Solution Overview
Problem
Filter elements in the automobile industry face issues with moisture absorption and deposit formation in foam seals, leading to compromised sealing effectiveness and potential detachment during installation.
Innovation Solution
A filter element with a seal made from a polymer material that penetrates into the fibrous filter medium using an extrusion method, providing high strength and sealing efficacy, along with rubber-elastic properties and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam seals are used for sealing the filter element, then sealing function is provided, but the seals absorb moisture and deposits form on them, reducing reliability
Solution Approach 1:
The patent changes the material parameters of the seal from foam material to thermoplastic material that is extruded at high temperature. This parameter change transforms the seal from a porous structure that absorbs moisture to a denser structure that resists moisture and deposits, thereby improving reliability while eliminating the harmful effects of moisture absorption.
Solution Approach 2:
The patent replaces the traditional foam sealing mechanism with an extrusion-based sealing mechanism. Instead of using foam that expands and seals, the invention uses thermoplastic material that is extruded under heat and pressure to create a seal that bonds to the filter medium, substituting the sealing mechanism to eliminate moisture absorption issues.
2Reliability
If glued-on foam seals are used, then sealing is achieved, but the seals may be sheared off during installation, reducing strength
Solution Approach 1:
The patent merges the seal with the filter medium by extruding thermoplastic material that penetrates and bonds directly to the filter medium fibers. This merging creates an integrated structure where the seal becomes part of the filter assembly, eliminating the separate glued-on foam seal that could be sheared off during installation.
Solution Approach 2:
The invention uses composite material structure where thermoplastic seal material is combined with the filter medium through extrusion. The thermoplastic material penetrates the fibrous structure of the filter medium, creating a composite structure with enhanced strength that resists shearing forces during installation while maintaining sealing functionality.
3Reliability
If traditional foam sealing method is used, then sealing is provided, but production time is extended due to curing and foaming processes, reducing productivity
Solution Approach 1:
The patent replaces the chemical-based foam curing process with a mechanical extrusion process. Instead of introducing foam that requires time to expand and cure, the invention uses thermoplastic material that is extruded under heat and pressure, allowing the seal to be formed and bonded in a single continuous operation, thereby eliminating the curing wait time and improving productivity.
Solution Approach 2:
The invention skips the time-consuming foam curing step by using thermoplastic extrusion. The high temperature and pressure of the extrusion process allow the seal material to be deposited and bonded to the filter medium immediately, rushing through the sealing process in one step rather than requiring separate foaming and curing stages, thus significantly reducing production time.
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 extrusion method ensures a strong, moisture-resistant seal with enhanced sealing performance and reduced production time, allowing for efficient and cost-effective manufacturing of filter elements with improved durability and functionality.
Implementation Method 1
the seal material penetrates into the fiber scrim of the filter medium and/or partially encloses these fibers, so that the seal material bonds to the fibers in a formfitting way
Implementation Method 2
the seal material bonds to the fibers in a formfitting way. This produces not only a high strength, but rather also a high sealing effect simultaneously
Implementation Method 3
Due to the high temperatures of approximately 200° C. which exist at the die during an extrusion method
Implementation Method 4
The seal has outstanding rubber-elastic properties, and simultaneously also has a stabilizing effect on the filter medium
Data Source
AI summary
A filter element, including a filter medium, on which a seal is situated indirectly or directly, which is used for separating the filter intake side from the filter discharge side. The filter medium comprises a fibrous material. The seal is applied indirectly or directly to the filter medium in the extrusion method (FIG. 1).