Molded Filter End Cap with Integrated Handle
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Solution Overview
Problem
Existing filter elements with handles often have mold split parting lines on the end caps, which can be aesthetically unappealing and may compromise the structural integrity and ease of use.
Innovation Solution
The filter element incorporates a handle structure unitarily molded into the end cap, featuring a flange with a void or grommet that creates a finger gripping aperture without a mold split, ensuring a durable and easy-to-use design while avoiding parting lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a handle structure is added to the filter element to facilitate removal, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The handle structure is merged with the end cap by unitarily molding them together as a single integrated component. The handle is not a separate attachment but is formed as an integral part of the end cap structure, eliminating the need for additional fastening mechanisms or separate handle components.
Solution Approach 2:
The end cap serves multiple functions: it seals the filter media and simultaneously provides an integrated handle for removal. The flange portion of the end cap acts both as a sealing surface and as a gripping surface, combining sealing and handling functions into a single structural element.
2Ease of manufacture
If a mold split is used to form the handle structure, then ease of manufacture is improved, but manufacturing precision deteriorates due to parting lines
Solution Approach 1:
The molding process transitions from a traditional split-mold approach to a single-piece mold that forms the handle structure in three dimensions without requiring parting lines. The mold body is designed as a monolithic structure that accommodates the complex geometry of the handle and end cap simultaneously.
Solution Approach 2:
The grommet is extracted as a separate component that is pre-placed into the mold cavity before the end cap material is injected. This allows the grommet to define the void space for the handle aperture without requiring the mold itself to split or form complex cavities.
3Ease of operation
If a grommet is molded into the flange to create a void, then ease of operation is improved through finger gripping, but device complexity increases
Solution Approach 1:
The grommet is a simple elastomeric component that self-defines the void space for the handle aperture through its own geometry. The grommet's outer surface sealingly engages the mold body walls, and its inner surface automatically creates the gripping void without requiring additional machining or forming operations.
Solution Approach 2:
The grommet is made from an elastomeric material that is compatible with the molding process and integrates seamlessly with the end cap material. The uniform elastomeric composition allows the grommet to be molded in place and provides consistent gripping properties throughout the handle structure.
Data Source
AI summary
A filter element including a filter media, a first end cap, and a second end cap is provided. The filter media has first and second filter ends. The first end cap is attached to the first filter end and the second end cap is attached to the second filter end. The second end cap is formed from a molded material and includes a handle structure unitarily molded therein. The handle structure includes a flange with a void formed at least partially transversely therethrough. The void is molded without a mold split such that no mold split parting line is formed on the second end cap. In one embodiment, the void is formed in the flange of the handle structure using a grommet molded therein.