Filter Element Winding Structure with Truss Frame
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Solution Overview
Problem
Existing fluid filter elements with non-cylindrical cores face challenges such as difficulty in achieving a secure seal, inefficient manufacturing processes, and high material usage due to corrugated center boards or complex core constructions, leading to increased costs and environmental impact.
Innovation Solution
A filter element with a winding structure featuring a truss-like frame and axial winding features that allow for efficient wrapping of fluted media, providing a secure seal and reducing material usage while facilitating easier manufacturing and disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluted filter media is coiled about a rectangular center board with corrugated regions, then the media can be held in place during winding, but the inherent shape memory of the media causes it to bow outwardly, making it difficult to create a secure seal between the first layer of media and the center board
Solution Approach 1:
The patent employs a disposable adhesive tape applied to the outer surface of the center board to secure the filter media during winding. This simple, low-cost disposable solution effectively counteracts the media's inherent shape memory that causes it to bow outward, creating a secure seal without requiring complex reusable mechanisms.
2Reliability
If a corrugated center board is used to help hold the fluted media in place, then the media can engage with the corrugations, but the corrugated section interferes with the ability of the media to move freely while being pulled by winding tension, and the media may not fit well into the corrugations due to dimensional tolerance variations
Solution Approach 1:
The patent uses a disposable adhesive tape applied to the center board's outer surface to secure the media, replacing the corrugated structure. This simple solution accommodates dimensional tolerance variations in the fluted media without interfering with the media's ability to move freely during winding, while still providing reliable retention.
Solution Approach 2:
The patent changes the securing mechanism from a rigid corrugated structure to a flexible adhesive tape, allowing the media to conform to the center board surface during winding while maintaining secure retention. This parameter change in the securing method's flexibility resolves the conflict between media retention and manufacturing precision.
3Adaptability or versatility
If a non-cylindrical central core is used to fit space constraints of the application, then the filter element can be formed into the required shape, but the inherent curvature memory of the filter media makes it difficult to create a secure seal between the first layer of media and the center board
Solution Approach 1:
The patent employs a disposable adhesive tape on the outer surface of the non-cylindrical center board to secure the filter media. This simple solution effectively counteracts the media's inherent curvature memory in non-cylindrical configurations, enabling secure seals to be created even when the center board has complex cross-sectional shapes like race track, oval, or rectangular profiles.
Data Source
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AI summary
A filter apparatus and method utilize a filter element, defining a longitudinal axis and an axial end thereof, and having a central winding structure and a length of fluted filter material wound about the winding structure with the flutes of the media oriented to provide for filtration of fluid passing axially through the filter element. An edge of filter media defines the axial end of the filter element when the media is wound about the winding structure. An axial end of the winding structure is disposed adjacent the axial end of the filter element. A winding feature extends substantially axially outward from the axial end of the winding structure to a distal end of the winding feature. The filter media is wrapped about the winding structure such that the axial end of the filter element is disposed substantially flush with the distal end of the winding feature.