Filter Cartridge Asymmetric Wave Geometry and Sealing
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Solution Overview
Problem
Conventional filter cartridges face issues with high impedance due to constant sectional areas in channels, inadequate sealing between filtering sheets, obstruction by unadhered adhesive layers, difficulty in cutting end sealing adhesive layers, and reduced filtering area due to adhesive flow, leading to inefficient fluid filtration.
Innovation Solution
The filter cartridge design involves pressing the peaks of the wavy filtering sheet towards the same direction to increase outlet sectional area, ensuring tight adhesion of end sealing adhesive layers, creating unobstructed channels, and using a gluing device to coat adhesive dots only on peaks, preventing interference with fluid flow, while the filter frame is designed to handle higher differential pressure with a resilient element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wavy filtering sheet is rolled with a 60-degree wave angle, then the filtering structure is formed, but the filter core is almost sealed between arching portions, preventing fluid passage
Solution Approach 1:
The wave angle is changed from the conventional 60 degrees to 45 degrees, creating an asymmetric modification in the wave geometry. This angular change prevents the arching portions from meeting and sealing the filter core, thereby maintaining fluid passage while preserving the filtering function.
2Strength
If a gluing gun coats elongated adhesives continuously across all peaks and troughs, then the filtering sheets are adhered, but most adhesive layers remain unadhered and interfere with fluid flow
Solution Approach 1:
The continuous adhesive coating is segmented into discrete adhesive dots positioned only on the peaks of the wavy filtering sheet. This segmentation ensures complete adhesion at each dot location while eliminating excess adhesive in the troughs that would otherwise obstruct fluid flow paths.
Solution Approach 2:
Adhesive is applied locally only where needed (on the peaks) rather than continuously across the entire surface. This localized application provides sufficient bonding strength at critical points while preventing adhesive interference in the fluid flow regions.
3Ease of manufacture
If the end sealing adhesive layer is coated but not solidified, then the adhesive can be applied, but the adhesive flows axially due to gravity, reducing filtering area
Solution Approach 1:
The filtering sheets are rolled into cylindrical shape immediately after adhesive application, before gravitational flow can occur. This preliminary rolling action secures the adhesive in place and prevents axial flow that would reduce the filtering area.
Solution Approach 2:
The process transitions from a static adhesive application to a dynamic rolling operation. The rolling action creates centrifugal and compressive forces that counteract gravitational flow, dynamically controlling adhesive placement and preventing area reduction.
4Device complexity
If the sectional area of channels is constant throughout, then the channel structure is simple, but impedance cannot be reduced
Solution Approach 1:
The channel sectional area is made asymmetric along the flow direction, with the outlet opening having a larger area than the inlet opening. This asymmetric geometry reduces impedance by facilitating easier fluid exit while maintaining structural simplicity.
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 design reduces impedance, enhances sealing reliability, increases filtering area, and allows for efficient fluid flow by ensuring adequate adhesion and channel clearance, while the resilient filter frame can withstand higher pressure.
Implementation Method 1
a resilient element (22)... seals a gap between the filter core (10) and the housing
Implementation Method 2
a first end sealing adhesive layer (14) and a second end sealing adhesive layer (15)... coated on the wavy filtering sheet (11)
Data Source
AI summary
A filter cartridge and a manufacturing method thereof, the manufacturing method has the following steps: adhering a wavy filtering sheet and a flat filtering sheet, pressing the filtering sheets, rolling the filtering sheets, and mounting a filter frame. A part of peaks of the wavy filtering sheet are pressed to lean toward a same direction, which has the following advantages. First, in a channel, an outlet opening is larger than an inlet opening in sectional area, thereby reducing the impedance. Second, a first end sealing adhesive layer is pressed to make said layer tightly connected to the filtering sheets, thereby making the seal reliable. Third, the pressed peaks lean toward a same direction, such that there are gaps large enough disposed between any two peaks in arching portions of the innermost circles of the filter core in the outlet side, which ensures the channels are unobstructed.