Filter Element Production via Film Web Wrapping and Longitudinal Welding
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Solution Overview
Problem
Existing methods for producing filter elements for industrial systems are inefficient and costly, requiring large quantities due to the need for frequent replacement when the filter mat becomes clogged, and involve complex processes like axial insert movement and thermal degradation to achieve prestress.
Innovation Solution
A method where a pre-assembled annular body of pleated filter mat web is wrapped with a flat film web, and the overlapping ends are connected by a longitudinal weld, eliminating axial insert movement and thermal prestress, using materials like polyamide or polyester with ultrasonic or laser welding, and optionally a welding filler for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the film web is placed around the annular body and clamped before connecting the overlapping ends, then the prestress of the filter mat becomes independent of pleat height tolerance and abrasion is eliminated, but the production process requires precise positioning and clamping mechanisms
Solution Approach 1:
The film web is clamped around the annular body before the overlapping ends are connected, establishing the prestress state in advance. This preliminary action ensures that the filter mat is pre-stressed to the correct tension before final assembly, making the prestress independent of pleat height variations that occur during production.
Solution Approach 2:
Instead of the conventional approach where the annular body is inserted into a pre-formed cylindrical outer sleeve, this invention forms the outer sleeve on the pre-assembled annular body. The film web is wrapped around and clamped to the annular body, then the overlapping ends are connected, inverting the traditional assembly sequence to achieve better prestress control and eliminate abrasion.
2Strength
If thermal welding is used to connect the overlapping end areas of the film web, then strong joining is achieved, but thermal degradation of the filter mat web may occur
Solution Approach 1:
The welding is applied locally only to the overlapping end areas of the film web, not to the entire assembly. This localized thermal application connects the film web ends strongly while minimizing thermal exposure to the filter mat web, preventing thermal degradation in the majority of the filter element structure.
Solution Approach 2:
The welding operation is performed quickly and efficiently to complete the joining before thermal degradation can occur. The process rushes through the critical thermal exposure phase, achieving strong bonding in a brief moment while minimizing the duration of thermal stress on the filter mat materials.
3Ease of operation
If the conventional method of gathering pleats into an insert cone is used, then introduction into the outer sleeve is facilitated, but the process remains complex and costly
Solution Approach 1:
The invention inverts the conventional assembly approach by forming the outer sleeve on the pre-assembled annular body rather than inserting the annular body into a pre-formed sleeve. This eliminates the need for complex insert cones and pleat gathering operations, simplifying the process while maintaining ease of assembly.
Solution Approach 2:
The formation of the outer sleeve and the assembly of the annular body are merged into a single integrated process. The film web is wrapped around and clamped to the pre-assembled annular body, combining what were previously separate operations (forming the sleeve and assembling the filter mat) into one streamlined process that reduces complexity and cost.
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 method simplifies production, reduces costs, and prevents abrasion and thermal degradation, enabling efficient and economical production of filter elements with improved prestress independence from pleat height tolerance.
Implementation Method 1
the end areas of the film web or more specifically the end areas of the at least one blank of the film web are typically connected together by forming a longitudinal weld
Implementation Method 2
joining can then be carried out by an ultrasonic welding process or by a welding laser
Implementation Method 3
joining can then be carried out by an ultrasonic welding process or by a welding laser
Data Source
AI summary
A method for producing a filter element for filtering fluids, such as hydraulic fluids, lubricants or fuels, includes the following steps: a) providing at least one section of a filter mat web (14) made of one or more layers of at least one filter medium; b) connecting the ends of the at least one section to form an annular body (12) and placing that annular body onto a support pipe (16); c) wrapping at least one cutout of a film web (8) around the outside of the annular body (12) located on the support pipe (16) and d) placing end areas (24) of the at least one cutout of the film web (8) one on top of the other and connecting the overlapping end areas (24).