Filter Assembly Two-Step Molding Sealing Method
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Solution Overview
Problem
Existing methods for manufacturing filter assemblies with pleated media packs in a frame structure are inefficient due to the high material and time requirements for sealing, which affects mechanical stability and precision in mounting.
Innovation Solution
A method involving a two-step molding process where the open ends of the media packs are sealed in the first step, forming stiffened edges that are then embedded in a second molding compound layer within the frame structure, reducing the need for adhesive material and curing time, and enhancing mechanical stability and precision in assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied to seal open ends of media packs in frame structure, then reliable seal is provided, but substantial amount of adhesive material is required and process is time consuming
Solution Approach 1:
The patent applies preliminary action by pre-sealing the open ends of media packs with adhesive strips before assembling them into the frame structure. This preliminary sealing ensures that the media packs are already sealed and ready for installation, eliminating the need for substantial adhesive application during the assembly process. The adhesive strips are applied to the edges of the media packs in advance, creating a ready-to-install component that maintains sealing reliability while reducing overall adhesive consumption.
2Reliability
If adhesive is applied to seal open ends of media packs in frame structure, then reliable seal is provided, but sealing process is time consuming
Solution Approach 1:
The patent applies preliminary action by pre-sealing the open ends of media packs with adhesive strips before assembling them into the frame structure. This preliminary sealing ensures that the media packs are already sealed and ready for installation, eliminating the need for substantial adhesive application during the assembly process. The adhesive strips are applied to the edges of the media packs in advance, creating a ready-to-install component that maintains sealing reliability while reducing overall adhesive consumption.
3Strength
If media packs are sealed to frame structure, then mechanical stability is provided, but precision in mounting is reduced
Solution Approach 1:
The patent applies local quality by providing localized sealing only at the open ends of the media packs where it is most needed for structural integrity and air flow control. The adhesive strips are applied precisely at the edges of the media packs rather than covering entire surfaces, which maintains mechanical stability at critical locations while preserving mounting precision. This localized approach allows for accurate positioning of media packs in the frame structure while still providing sufficient mechanical bonding strength.
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 simplifies the manufacturing process, reduces material usage, and improves the mechanical stability and precision of the filter assembly's sealing, resulting in a more efficient and reliable filter assembly with enhanced air flow and extended application life.
Implementation Method 1
The molding compound layer is then allowed to cure. This manner of sealing the media pack to the housing generally may provide a reliable seal
Data Source
Figure 1a~1b
Figure 1c~2a
Figure 2b~2c
AI summary
The present invention relates to a filter assembly comprising at least one media pack arranged in a frame structure in which the at least one media packs is pleated and having opposing first and second open ends, and a corresponding method for manufacturing such a filter assembly for removing particles from an air stream. The method for manufacturing a filter assembly for removing particles from an air stream said comprises for each media pack sealing the first and second open ends in a first molding step, thereby providing a sealed first edge and a sealed second edge of each respective media pack, and subsequently arranging the at least one media pack in the frame structure and in a second molding step securing and sealing the sealed first edge and the sealed second edge, respectively, to at least one frame element of the frame structure.