Filter Element Mounting Frame with Adhesive Containment Channel
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Solution Overview
Problem
Larger filter elements face issues with dimensional consistency, leading to leak paths between the mounting frame and filter media pack, which reduces the securement and aesthetic appeal of filtration systems.
Innovation Solution
The use of a mounting frame with an inner and outer wall forming a gap, filled with a shut-off material that radially contacts the filter media pack's outer periphery, and an adhesive within a cavity formed by the walls, secures the frame to the media pack, preventing adhesive leakage and enhancing the seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If filter elements are made larger to increase production capacity, then productivity is improved, but dimensional consistency deteriorates leading to leak paths between frame and media pack
Solution Approach 1:
The patent applies parameter changes by modifying the adhesive application parameters - specifically applying adhesive in a controlled pattern (annular pattern at outer periphery, radial lines from center) with specific viscosity ranges (100-10,000 cP) and application quantities (0.1-10 mL). This compensates for dimensional variations in larger filter elements, ensuring proper bonding between frame and media pack despite increased size and associated dimensional inconsistencies.
Solution Approach 2:
The adhesive acts as an intermediary substance between the mounting frame and filter media pack. By carefully controlling adhesive properties (viscosity, application pattern, quantity), it mediates the connection between components that have dimensional variations, preventing leak paths while maintaining the structural integrity needed for higher productivity applications.
2Strength
If adhesive is applied to secure mounting frame to filter media pack, then bonding strength is improved, but adhesive leakage occurs reducing aesthetic appeal
Solution Approach 1:
The patent applies local quality by varying the adhesive application pattern - using an annular pattern at the outer periphery for strong edge bonding, radial lines from the center for distributed bonding, or combinations thereof. This localized application strategy ensures adequate bonding strength at critical areas while minimizing adhesive in regions prone to leakage, thus preventing aesthetic issues while maintaining structural integrity.
Solution Approach 2:
The patent applies partial action by using specific adhesive quantities (0.1-10 mL) and patterns rather than uniform full coverage. This controlled partial application provides sufficient bonding strength for the mounting frame attachment while avoiding excessive adhesive that would leak and compromise aesthetic appearance.
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 solution ensures a secure and leak-proof attachment of the filter element to the housing, maintaining the aesthetic appeal and functionality of filtration systems by compensating for dimensional inconsistencies and preventing adhesive leakage.
Implementation Method 1
The shut-off material is positioned within the gap and extends out of the gap and into radial contact with the outer periphery of the filter media pack
Implementation Method 2
The adhesive is located within the cavity and secures the mounting frame to the filter media pack
Data Source
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AI summary
A filter element with an improved mounting frame and method of assembly are provided. The filter element includes a filter media pack with a mounting frame attached to the outer periphery of the filter media pack. The mounting frame defines a channel that holds a shut-off material for preventing leakage of an adhesive securing the mounting frame to the filter media pack. A filter element that includes a polymeric material between the filter media pack and the adhesive is also provided. The shut-off material may be pre-formed or applied in a flowable state.