Filter Element Plate Integration for Secure Attachment

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Solution Overview

Problem

Conventional filter devices for air intake systems require multiple parts and complex processing, leading to high manufacturing costs and unsatisfactory attachment strength due to the need for separate resin frames and attachment holes, as well as inadequate joining of fuel adsorbing sheets to supports.

Innovation Solution

A filter device with a sheet-like filter element featuring a plate-like portion integrally formed around its periphery, crimped portions secured to supports, and protrusions rising through the plate-like portion, which are formed by heating and pressing to securely attach the filter element to the support using a specialized tool with a pressing protrusion and annular rib.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate resin frame is attached to the fuel adsorbing sheet with multiple attachment holes, then the filter element can be secured to the support, but the number of parts increases and processing becomes troublesome leading to high manufacturing costs

Engineering Contradiction:

Improveattachment strengthVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the resin frame and fuel adsorbing sheet into a single integrated structure. The plate-like portion is formed integrally with the fuel adsorbing sheet through thermal pressing, eliminating the need for a separate resin frame and reducing the number of parts while maintaining attachment functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plate-like portion is pre-formed with crimped portions and attachment holes before installation. The protrusions are pre-formed on the support, allowing for simplified assembly where the filter element is simply placed over the support and the protrusions automatically engage with the attachment holes.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple attachment holes are created in the resin frame, then the filter element can be secured to the support, but the strength of the resin frame and outer periphery of the fuel absorbing sheet decreases

Engineering Contradiction:

Improveattachment strengthVSAvoidresin frame strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The plate-like portion is thermally pressed to create localized crimped portions at specific attachment points rather than creating multiple through-holes throughout the entire frame. This concentrates the structural reinforcement where needed while preserving the overall strength of the plate-like portion.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The crimped portions and attachment holes are pre-formed in the plate-like portion during the thermal pressing process before installation. The protrusions are pre-formed on the support, allowing for simplified assembly where the filter element is simply placed over the support and the protrusions automatically engage with the attachment holes.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If ultrasonic waves are applied only to the contact area between the plate-like portion and support, then joining occurs at the contact area, but the attachment strength is not satisfactory

Engineering Contradiction:

Improvejoining processVSAvoidattachment strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The attachment system is segmented into discrete crimped portions at specific locations on the plate-like portion and corresponding protrusions on the support. This segmentation allows for concentrated welding energy at each attachment point rather than distributing energy across the entire contact area, resulting in stronger localized bonds.

Inventive Principle:

Principle #1Segmentation

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 reduces the number of parts, simplifies processing, enhances attachment strength, and eliminates the need for resin frames and attachment holes, resulting in lower manufacturing costs and improved securement of the filter element.

Implementation Method 1

A plate-like portion of the filter element is pressed against a support inside the casing while being heated, so that a crimped portion that is secured to the support is formed

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a protrusion which is integrally formed with the support around the crimped portion and rises through the plate-like portion

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS7811350B2Filter device, manufacturing method for the same, and filter element securing tool

Publication Date: 2010.10.12 TOYOTA BOSHOKU KK

AI summary

A sheet-like filter element is installed on a support within the casing of a filter device. A plate-like portion is integrally formed in at least the outer periphery of the filter element. A crimped portion which is to be secured to the support in a crimped state is formed in this plate-like portion. A protrusion which rises through the above described plate-like portion is formed so as to be integrated with the above described support around this crimped portion. The plate-like portion is secured to the support by means of this protrusion.