Filter Mat Web Layer Connection Zones Prevent Delamination
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Solution Overview
Problem
Existing filter mat webs face challenges in maintaining dimensional accuracy, homogeneity, and stability due to delamination issues during manufacturing and operation, especially under mechanical stresses from flow forces, which affect their performance and safety.
Innovation Solution
The method involves connecting individual layers separately and then integrating them with connection areas that lie on top of, cross, or run alongside each other, rather than at the edges, to form a structurally stable filter mat web, using techniques like welding or needling, and arranging these connections in patterns or linear paths to enhance stability and prevent delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual layers are connected at the filter mat ends to close the tubular body, then the filter element can be assembled, but delamination occurs during handling and operation under mechanical stresses
Solution Approach 1:
The filter mat web is divided into multiple individual layers that are connected in groups rather than as a single continuous structure. Each group of layers is connected separately in a first connection step, and assignable groups are connected in a second connection step, creating segmented connection zones that prevent stress concentration and delamination while maintaining assembly capability.
Solution Approach 2:
Connection areas are strategically positioned within the filter mat web at defined distances from edge regions, creating local zones of enhanced stability. The connection areas have different properties than the surrounding filter material, providing localized reinforcement that prevents delamination during handling and operation without affecting the overall filter performance.
2Reliability
If multiple layers are connected together to form a multi-layer structure, then filter performance is improved, but dimensional accuracy and homogeneity become difficult to maintain
Solution Approach 1:
The multi-layer structure is divided into manageable groups of individual layers, with each group connected separately. This segmentation allows for precise control of each layer group during manufacturing while maintaining the overall multi-layer filter performance. The separate connection steps enable better dimensional control compared to connecting all layers simultaneously.
3Reliability
If connection areas are placed within the filter mat web at a distance from edge areas, then delamination is prevented, but the connection process becomes more complex
Solution Approach 1:
The connection process is segmented into two distinct steps: first connecting individual layers within groups, then connecting assignable groups together. This segmentation of the connection process, while adding a step, simplifies each individual connection operation and enables better control over connection quality and delamination prevention.
Solution Approach 2:
Individual layers are connected into groups in a preliminary first connection step before the groups are connected together in a second step. This preliminary action of forming stable layer groups first makes the subsequent connection process more manageable and ensures that delamination is prevented from the outset during handling and operation.
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 approach significantly increases the operational safety and stability of the filter mat web, ensuring reliable performance even at high flow rates and improving differential pressure stability and long-term behavior by preventing layer delamination and deformation.
Implementation Method 1
connecting the individual layers separately and then integrating them with connection areas that lie on top of, cross, or run alongside each other, rather than at the edges, to form a structurally stable filter mat web, using techniques like welding or needling
Data Source
Figure 1
Figure 2~5
Figure 6~8
AI summary
A filter element having a filter mat web consisting of at least one group of at least two individual layers (25, 27, 29, 31) that are adjacent to one another and are to be joined, wherein the joining proceeds in defined connection regions (5), is characterized in that at least a majority of the connection regions (5) is arranged within the filter mat web at a distance from edge regions thereof, and in that the connection regions (5) of the individual layers (25, 27, 29, 31) of the respective groups are congruent to one another in such a manner that delamination of layers (25, 27, 29, 31) of the filter mat web (1) is prevented.