Filter Element Comb-Shaped Reinforcing Rib Insert Molding

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Solution Overview

Problem

Conventional filter elements with integrally formed reinforcing ribs suffer from reduced effective filtration area due to mold compression, leading to increased size and filtration resistance, and protruding resin burrs that obstruct the filtration process.

Innovation Solution

A filter element with a comb-shaped member inserted into pleat portions of the filter member, formed through insert-molding, which acts as a reinforcing rib without compressing the filter surface, ensuring the effective filtration area and preventing separation during fluid flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a reinforcing rib is formed integrally with the filter member through insert-molding process, then the pleated shape and rigidity are maintained and adjacent gathers are prevented from contacting, but the fused synthetic resin protrudes as burrs on the filter member surface and reduces effective filtration area

Engineering Contradiction:

Improverigidity of frame bodyVSAvoidsurface quality of filter member

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

A release agent is introduced as an intermediary substance between the filter member and the synthetic resin during injection molding. The release agent prevents the resin from directly bonding to the filter member surface, eliminating burr formation while maintaining the reinforcing rib's structural function. This mediator layer allows clean separation after molding without damaging the filter member.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The harmful effect of resin adhesion to the filter member is extracted and separated from the molding process. By applying a release agent, the unwanted bonding between resin and filter member is prevented, allowing the reinforcing rib to be formed without the harmful side effect of burr formation on the filtration surface.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If the boundary of the frame body or reinforcing rib is compressed by using a mold to prevent resin seepage, then burr formation is prevented, but the filter member surface is clogged and effective filtration area is reduced

Engineering Contradiction:

Improvesurface quality of filter memberVSAvoideffective filtration area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The release agent serves as a mediator that prevents resin adhesion without requiring mechanical compression of the filter member. This eliminates the need to compress the filter surface to prevent burrs, thereby avoiding clogging of the filtration area while still achieving burr-free surfaces through chemical prevention of adhesion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical compression method is replaced with a chemical approach using a release agent. Instead of applying mechanical pressure to prevent resin seepage (which clogs the filter), a chemical substance prevents adhesion, eliminating the need for compressive force and preserving the filtration surface integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If both sides of the reinforcing rib are compressed to prevent resin seepage, then burr formation is prevented, but the filter element size enlarges and manufacturing complexity increases

Engineering Contradiction:

Improvesurface quality of filter memberVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The complex mechanical compression system requiring clamping of both sides of the reinforcing rib is replaced with a simple chemical application of release agent. This substitution eliminates the need for complex molding adjustments and reduces manufacturing process complexity while achieving the same burr prevention goal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The harmful adhesion effect is extracted and addressed separately through release agent application, eliminating the need for complex mechanical compression systems. This simplifies the manufacturing process by removing the requirement for sophisticated mold compression mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If the filter element size is increased to accommodate compression areas, then resin seepage is prevented, but the effective filtration area is reduced and the filter element becomes larger

Engineering Contradiction:

Improvesurface quality of filter memberVSAvoideffective filtration area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The mechanical compression approach that requires additional space is replaced with chemical release agent application. This allows burr prevention without needing to allocate additional filter area for compression zones, thereby maintaining maximum effective filtration area without enlarging the filter element.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2769758B1Filter element

Publication Date: 2017.03.22 ROKI CO LTD

AI summary

A filter element includes a filter member provided with a plurality of pleat portions and a frame body holding an outer peripheral portion of the filter member. The frame body is provided with a comb-shaped portion having a comb-tooth portion which is inserted into adjacent pleat portions and contacts to a surface of the filter member, and the comb-shaped member is formed by an insert-molding process.