Filter Core Corrugated Channels Flame Cutting
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Solution Overview
Problem
Conventional filter cores have insufficient filtering effects due to direct fluid passage through adhesive layers and uneven cut edges from press-cutting methods, which deform and flatten the filtering sheets, leading to inefficient pollutant removal and structural integrity issues.
Innovation Solution
A filter core design featuring corrugations on both wavy and flat filtering sheets, forming concave and convex portions on channel inner walls, with axial and end sealing adhesive layers to enhance filtration and prevent edge deformation during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a press cut is used to directly press downward to achieve cutting, then the cutting process is simple and fast, but the movement of the press cut flattens and deforms the cut edge of the adhered filtering sheets, making the edge of the adhered filtering sheets and the edge of the rolled filter core uneven
Solution Approach 1:
The patent replaces the mechanical press-cutting system with a flame-cutting system. Instead of using a pressing blade to directly cut the adhered filtering sheets, a flame source is used to heat and cut the material. This substitution eliminates the mechanical contact that causes flattening and deformation of the cut edges, while maintaining efficient cutting speed.
Solution Approach 2:
The patent introduces an intermediary substance (adhesive) between the filtering sheets and the cutting process. The adhesive layer protects the filtering sheets during cutting, preventing direct mechanical contact and deformation. The flame cutting method heats through the adhesive and filtering sheets without causing edge flattening, thus preserving edge flatness while achieving efficient cutting.
2Speed
If the fluid passes directly through the wavy filtering sheet or the flat filtering sheet to arrive at the other half of the channels, then the fluid flow path is short and flow resistance is low, but the filtering effect is insufficient
Solution Approach 1:
The patent transforms the straight fluid flow path into a curved path by designing the channels to follow the corrugated structure of the filtering sheets. The fluid must flow along the undulating surface created by the alternating wavy and flat sheets, increasing the effective filtering path length without significantly increasing flow resistance. This curvature ensures the fluid contacts more filtering surface area, enhancing the filtering effect while maintaining acceptable flow speed.
3Productivity
If multiple channels are formed between the wavy filtering sheet and the flat filtering sheet with end sealing adhesive layers, then the fluid can flow through multiple paths, but the fluid directly passes through the filtering sheets without adequate filtering
Solution Approach 1:
The patent applies different qualities to different parts of the filtering structure. The wavy filtering sheets provide structural support and define channel geometry, while the flat filtering sheets provide the primary filtering surface. The alternating arrangement creates zones of different filtering intensity along the fluid path, ensuring that fluid passes through multiple filtering surfaces with varying characteristics, thereby maintaining both flow capacity and filtering effectiveness.
Data Source
AI summary
A filter core has a wavy filtering sheet and a flat filtering sheet. The filtering sheets are for filtering suspended pollutants and respectively have multiple corrugations axially arranged apart from each other. Therefore, channels formed between the filtering sheets also have corrugations formed on inner walls of the channels after the filtering sheets are adhered. The corrugations on the inner walls of the channels are also axially arranged apart from each other and form concave and convex portions. As a result, when fluid, such as air, axially moves in the channels, the suspended pollutants on the fluid may hit, gather and accumulate on the corrugations, thereby slowing the fluid flow and providing one more filtering process. In addition, the corrugations on the filtering sheets also increase a filtering area. To sum up, the filter core can enhance the filtering effect.