Filter Material Fold Geometry Stabilization
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Solution Overview
Problem
Existing filter materials for hydraulic systems face challenges in maintaining fold geometry stability, especially under high differential pressures and viscous fluid flow, leading to operational disruptions and increased wear due to 'fold block formation' and reduced dirt pickup.
Innovation Solution
A filter material with an additional folded layer of fluid-permeable, flexible support material forming an 'inner star' geometry that stabilizes individual folds and maintains distance between them, which can be made from carbon or glass fiber prepreg materials that harden during the folding process, and can be applied as an outer layer or integrated within the filter mat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If band-shaped ring elements are placed around the outside of the filter material with connection points formed by weld points, then the fold geometry is stabilized, but the production process becomes more complex and expensive due to a large number of welding processes
Solution Approach 1:
The invention extracts the stabilizing function from external band-shaped ring elements and integrates it directly into the filter material structure through thermoplastic layers that are molded in during the forming process, eliminating the need for separate welding operations while maintaining fold geometry stability
Solution Approach 2:
The stabilizing thermoplastic layers are merged with the filter material layers during the molding process, creating an integrated structure where the stabilizing function is combined with the filtration function, thereby simplifying production by eliminating separate welding steps
2Stability of the object's composition
If stabilizing means are provided in the form of band-shaped ring elements placed around the outside of the filter material, then the fold geometry is stabilized, but the device structure becomes more complex
Solution Approach 1:
The stabilizing thermoplastic layers are nested between the filter material layers during the molding process, creating a compact integrated structure where the stabilizing function is embedded within the filter element itself rather than added as external components
Solution Approach 2:
The invention uses composite material structures combining filter material layers with thermoplastic stabilizing layers that are molded together, creating a unified composite element that provides both filtration and structural stability without requiring separate components
3Ease of manufacture
If the support material layer is made flexible so it does not break when folded, then the folding process is enabled, but the stabilizing effect may be reduced
Solution Approach 1:
The thermoplastic layers undergo parameter changes during the molding process, transitioning from a flexible state during folding to a rigid stabilized state after cooling, thereby achieving both foldability during manufacturing and geometric stability during operation
Solution Approach 2:
The thermoplastic stabilizing layers utilize phase transitions during the molding process, being in a pliable state during forming and transitioning to a rigid stabilized state upon cooling, enabling both easy folding and strong geometric stability
Data Source
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AI summary
A filter material, in particular for hydraulic installations, with a filter mat (1) which preferably consists of a plurality of layers of a filter medium and which is provided with a succession of pleat-like folds, wherein, in order to secure the fold geometry against deformation, at least one stabilizing means (19) which acts on portions of the filter mat (1) is provided, is characterized in that the filter mat (1) has as stabilizing means at least one further folded layer (19) of a reinforcing supporting material.