Radiation Welding Filter Element Outer Shell Fitment
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Solution Overview
Problem
Existing methods for connecting subcomponents of filter elements using laser transmission welding are limited by the need for materials with different optical properties, requiring additional steps and materials like barrier layers or absorbers, which restrict material selection and can result in poor fitment of outer shells to filter mats.
Innovation Solution
A method where the melting area is produced in the radiation-permeable subcomponent, eliminating the need for radiopaque materials and intermediate films, allowing direct connection of subcomponents with similar optical properties using focused radiation, enabling optimal adaptation of the outer shell to the filter mat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser transmission welding is used to connect subcomponents, then the connection process can be automated and production efficiency improved, but the material selection is restricted to components with different optical properties requiring additional barrier layers or absorbers
Solution Approach 1:
Instead of using a laser-absorbing barrier layer between components, the patent inverts the approach by using a laser-transparent barrier layer that allows the laser beam to pass through to the second component. This enables both components to be made from the same or similar transparent materials while still achieving effective welding through the barrier layer.
Solution Approach 2:
The barrier layer acts as an intermediary element that is specifically designed to be laser-transparent rather than absorbing. This intermediary allows the laser energy to transmit through it to the second component, enabling welding without requiring the barrier layer to absorb the laser energy, thus expanding material selection flexibility.
2Reliability
If a barrier layer impermeable to laser radiation is used between subcomponents, then the laser energy can be absorbed and thermoplastic material can be melted for welding, but additional work steps and expensive additives or surface coatings are required
Solution Approach 1:
The patent inverts the traditional barrier layer concept by making the barrier layer laser-transparent instead of laser-absorbing. This allows the laser beam to pass through the barrier layer and directly heat the second component for welding, eliminating the need for additional absorptive coatings or complex multi-layer structures.
Solution Approach 2:
The patent extracts the absorptive function from the barrier layer by making the barrier layer transparent and instead using the second component itself as the heat absorption medium. This simplifies the overall structure by removing the need for specialized absorptive barrier layers and associated additives.
3Strength
If a prefabricated outer shell is used to encase the filter element, then the structural integrity can be improved, but the outer shell either fits too closely to the filter mat or is partially spaced from it, leaving no tolerance compensation
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism where the outer shell can be selectively positioned at different radial positions. This allows the shell to adapt to variations in filter mat diameter, providing tolerance compensation while maintaining structural integrity through controlled positioning rather than fixed prefabrication.
Solution Approach 2:
The patent enables parameter changes in the outer shell's radial position to accommodate different filter mat diameters. By allowing the shell to be positioned at varying radial distances from the filter mat, the system can compensate for tolerances while maintaining a secure fit and structural strength.
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 the connection process, expands material selection, and ensures a precise fitment of the outer shell to the filter mat, reducing unnecessary work steps and material costs while maintaining recyclability and avoiding undesired color effects or deformation.
Implementation Method 1
at least one of the subcomponents to be connected to one another is formed from a thermoplastic radiation-permeable material and is at least partially irradiated by means of radiation, the radiation being so focused in at least one fused area of the at least one subcomponent that by material melting, at least in the respective melting area, the subcomponents are firmly connected to one another after they have cooled down
Implementation Method 2
by material melting, at least in the respective melting area, the subcomponents are firmly connected to one another after they have cooled down
Implementation Method 3
at least one of the subcomponents to be connected to one another is formed from a thermoplastic radiation-permeable material and is at least partially irradiated by means of radiation
Data Source
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AI summary
The invention relates to a method for joining part components (10, 12) of a filter element, at least one of the part components (10, 12) to be joined being formed from a thermoplastic material which is transparent to radiation and through which at least one radiation (14) shines at least partly. Said method is characterized in that the radiation (14) is focused in at least one fusing region (20) of the at least one partial component (10, 12) in such a way that, by means of material melting, the partial components are firmly joined to one another at least in the respective fusing region (20) after having cooled down.