Filter Media Layer Compression Cracking Prevention

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Solution Overview

Problem

Existing methods for manufacturing multi-filter media layer filter cartridges often result in cracking of the uppermost filter media layer during compression, leading to potential leaks and reduced effectiveness, and require multiple inlet configurations, complicating the manufacturing process.

Innovation Solution

Incorporating spacer seals between filter media layers to equalize bending radius and using a single inlet design configuration, which eliminates the need for multiple inlet parts by adjusting compression to prevent cracking and ensure a leak-proof seal during the overmolding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple inlet configurations are used to accommodate different filter media layer arrangements, then the filter cartridge can be adapted to various filtering needs, but the manufacturing process becomes more complex and requires multiple inlet parts

Engineering Contradiction:

Improveadaptability to different filter media layer arrangementsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inlet component is designed with a universal structure that can accommodate different numbers and arrangements of filter media layers through adjustable compression mechanisms, eliminating the need for multiple specialized inlet parts for different configurations

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If compression force is applied to seal the filter media layers during overmolding, then a leak-proof seal is achieved, but the uppermost filter media layer cracks due to excessive pressure

Engineering Contradiction:

Improveseal integrityVSAvoidfilter media layer integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The inlet component incorporates localized compression features that apply sealing pressure specifically at the interface between the inlet and filter media layers, rather than uniform compression across all layers, thereby achieving a leak-proof seal without cracking the uppermost layer

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The filter media layers are pre-positioned and supported on the outlet component before the overmolding process begins, ensuring proper alignment and distribution of compression forces during sealing to prevent cracking

Inventive Principle:

Principle #10Preliminary action

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

The solution effectively prevents cracking of filter media layers and simplifies the manufacturing process by using a single inlet configuration, ensuring a robust and leak-proof seal for both single and multi-filter media layer cartridges.

Implementation Method 1

a thermoplastic overmold, operatively injection molded over the periphery of the inlet, the outlet and the at least one porous filter media, sealing the periphery of the inlet, the outlet and the at least one porous filter media

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

a structural component operatively position proximate the outer periphery of the bottom surface of the inlet for operatively interacting with the upper portion of the single filter media layer by increasing the compression on the top filter media layer to ensure that the pores of the single media layer is sufficiently collapsed

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS8636151B2Method of preventing filter media cracking when compressing two or more filter media layers

Publication Date: 2014.01.28 SOLVENTUM INTELLECTUAL PROPERTIES CO

AI summary

The present disclosure generally relates to injection molded thermoplastic single filter media layer and multi-filter media layer filter cartridges that include a novel arrangement of structural features to improve both the quality of the manufacturing process and the integrity of the filter media layer seal and more particularly to a process for manufacturing both single filter media layer and multi-filter media layer filter cartridges and to the single filter media layer and the multi-filter media layer filter cartridges produced thereby and even more particularly to a process for manufacturing a multi-filter media layer filter cartridge without cracking the upper most filter media layer or any filter media layer during the compressing of at least two porous filter media layers between an inlet and an outlet while insuring an effective seal and the multi-filter media layer filter cartridges produced thereby and, yet, more particularly, to single filter media layer and the multi-filter media layer filter cartridges using only a single inlet design configuration and a single outlet design configuration for manufacturing a plurality of different single filter media layer filter cartridge configurations and a plurality of different multi-filter media layer filter cartridge configurations.