Filter Core Configuration with Annular Walls
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Solution Overview
Problem
Existing water filtration systems for pitchers and other fluid containers face issues such as bypass due to vertical seams in filter medium attachments, complications in manufacturing with glue, and increased costs and complexity from using mechanical devices like O-rings and clamps.
Innovation Solution
A filter core configuration with annular walls and a dual wrap filter medium laminate, including activated carbon fiber between non-woven layers, securely attached without glue, reducing bypass and eliminating the need for mechanical devices, while enabling dual filtration in a single pass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter medium is attached to filter core with glue, then filter medium can be secured to filter core, but manufacturing process becomes complicated and consumer perception is negatively affected
Solution Approach 1:
The patent replaces the chemical bonding method (glue) with a mechanical attachment system consisting of a filter core with external peripheral surfaces and a filter medium with attachment features that mechanically engage with the core. This substitution eliminates the need for adhesives while maintaining secure attachment, thereby simplifying the manufacturing process and improving consumer perception.
2Reliability
If O-rings and clamps are used to prevent bypass, then fluid sealing is improved, but device cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates the need for separate sealing components like O-rings and clamps by integrating sealing functionality directly into the filter core and filter medium structure. The attachment features are designed to provide both mechanical support and fluid sealing through the inherent geometry of the engaged surfaces, removing the need for additional sealing devices and reducing overall system complexity.
Solution Approach 2:
The patent merges the functions of mechanical attachment and fluid sealing into a single integrated structure. The attachment features on the filter medium and corresponding surfaces on the filter core simultaneously provide both structural support and sealing action, combining what were previously separate functions into one unified mechanism.
3Ease of operation
If vertical seam is created in filter medium attachment, then filter medium can be wrapped around filter core, but fluid bypass through seam reduces filtration effectiveness
Solution Approach 1:
The patent transitions from a two-dimensional flat filter medium to a three-dimensional configuration where the filter medium is contorted or folded to eliminate seams. By adding dimensional complexity to the filter medium structure, the solution maintains the wrapping capability around the cylindrical filter core while eliminating the vertical seam that caused bypass, thereby preserving filtration effectiveness.
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 effectively minimizes bypass, extends filter medium life, and enhances filtration effectiveness by ensuring all fluid passes through multiple layers of the filter medium, meeting NSF standards for chlorine reduction even at higher flow rates.
Implementation Method 1
a filter medium, such as a laminate including a layer of activated carbon fiber (ACF) media positioned between two layers of non-woven material
Data Source
AI summary
In one example, a filter core includes a body with a generally cylindrical shape and a substantially hollow interior. The body includes a first annular wall disposed proximate a first end of the body, and a second annular wall disposed proximate a second end of the body such that the second annular wall is axially spaced apart from the first annular wall, and the second annular wall and the first annular wall extend toward each other. As well, the filter core includes a framework connected to the first annular wall and the second annular wall. The framework and the first and second annular walls cooperate with each other to define a group of openings, each of which communicates with the substantially hollow interior of the body, and the openings collectively define an open space of the filter core.