Filter Core Adhesive Concentration and Pressing Method
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Solution Overview
Problem
Conventional filter core manufacturing methods face issues with inadequate adhesion and excess glue usage, leading to inefficient sealing and increased manufacturing time, particularly due to the spreading of end sealing adhesive layers during the pressing process, which results in incomplete sealing and reduced filtering area.
Innovation Solution
The method involves adhering a wavy filtering sheet to a flat filtering sheet with a first end sealing adhesive layer, pressing the sheets to concentrate the adhesive, and then rolling them with a second end sealing adhesive layer to form a filter core, allowing for secure adhesion with less glue and omitting the cutting step, thereby enhancing adhesion and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger quantity of glue is used to form the end sealing adhesive layer, then the adhesion between filtering sheets is improved, but the manufacturing time is increased due to longer solidification time
Solution Approach 1:
The patent changes the physical-chemical parameters of the adhesive by selecting specific materials (hot melt adhesive, epoxy adhesive, or polyurethane adhesive) with different solidification characteristics. This allows achieving adequate adhesion with smaller quantities while maintaining reasonable solidification times, thus resolving the contradiction between adhesion strength and manufacturing time
Solution Approach 2:
The pressing roller acts as an intermediary that facilitates uniform adhesive distribution and enhances adhesion without requiring large amounts of glue. The pressing mechanism ensures proper bonding while maintaining efficient manufacturing throughput
2Reliability
If larger quantity of glue is used to form the end sealing adhesive layer, then the sealing effectiveness is improved, but the glue leakage is increased
Solution Approach 1:
By changing the material parameters of the adhesive and controlling the quantity applied, the patent achieves effective sealing with reduced leakage. The pressing process parameters are also optimized to ensure proper adhesive distribution without excess
Solution Approach 2:
The patent applies adhesive in a controlled, partial manner rather than excessive coverage. The adhesive is applied to specific regions where sealing is needed, and the pressing process ensures adequate bonding without requiring excessive adhesive quantities that would lead to leakage
3Area of stationary object
If the end sealing adhesive layer is coated closer to the edge of the filtering sheet, then the filtering area is increased, but the adhesive spreading causes insufficient adhesion
Solution Approach 1:
The pressing operation is performed as a preliminary action immediately after adhesive application. This preliminary pressing ensures the adhesive is properly distributed and bonded before any potential spreading can occur, allowing the adhesive to be positioned closer to the edge while maintaining adequate adhesion strength
Solution Approach 2:
The patent optimizes the parameters of the pressing process (pressure, duration, temperature) to control adhesive behavior. This allows the adhesive layer to be positioned closer to the filtering sheet edge, maximizing filtering area while preventing insufficient adhesion through controlled pressing parameters
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 ensures uniform adhesive distribution, prevents bubbling, and allows for a larger filtering area with reduced glue usage, accelerating the solidification process and eliminating the need for cutting, thus improving the manufacturing efficiency and sealing effectiveness.
Implementation Method 1
a first end sealing adhesive layer, which is coated on the first surface and spread along the outlet side, and is arranged apart from the outlet side; the flat filtering sheet for filtering suspended pollutants is adhered with the first surface of the wavy filtering sheet by the first end sealing adhesive layer
Data Source
AI summary
A filter core and manufacturing method thereof, the manufacturing method has the following steps: adhering a wavy filtering sheet and a flat filtering sheet, pressing the filtering sheets, and rolling the filtering sheets. A part of peaks of the wavy filtering sheet are pressed to lean toward a same side. In particular, two sides of a first end sealing adhesive layer are pressed. Thus, the first end sealing adhesive layer is concentrated, such that the glue is uniformly spread to the two sides. Besides, the pressing on the two sides makes the two sides of the first end sealing adhesive layer adhered securely, thereby preventing the wavy filtering sheet from rebounding upward and forming bubbles. Thus, the first end sealing adhesive layer can be formed with less quantity of glue, which accelerating the cooling and raises manufacture efficiency.