Coreless Filter Media Winding with Dynamic Torque Control
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Solution Overview
Problem
Existing methods for winding filter media packs into non-circular shapes, such as oblong or race-track shapes, are complex and often require manual operations, leading to inefficiencies and media deformations, and lack adequate tension control.
Innovation Solution
A winding apparatus that uses controlled linear speed and variable torque to wind fluted filter media into desired shapes without cores, employing movable web guides and adhesive applicators to form half-peaks at edges, and featuring interchangeable tooling for various shapes, allowing for coreless or core-based winding with precise tension management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If complex conveyor mechanisms and machinery are used for winding non-circular media packs, then the desired shape can be achieved, but the device complexity increases and manual operations are still required
Solution Approach 1:
The patent employs a dynamic winding system where the mandrel rotates at variable speeds during the winding process. The rotation speed is adjusted based on the position of the media pack to maintain proper tension and achieve the desired non-circular shape (oval, race-track, or rectangular) without requiring complex conveyor mechanisms. This dynamic control allows a single apparatus to handle multiple shapes.
Solution Approach 2:
The winding apparatus is designed with universal tooling that can produce multiple media pack shapes (circular, oval, race-track, rectangular) using the same basic mechanism. By adjusting winding parameters and tooling configurations rather than requiring different complex machinery for each shape, the system achieves multi-functionality while reducing overall device complexity.
2Manufacturing precision
If manual trimming operations are performed to form leading and trailing edges, then precise positioning through peaks can be achieved, but productivity decreases
Solution Approach 1:
The system performs preliminary positioning of the media web before winding begins. The web is pre-aligned and pre-trimmed to ensure that leading and trailing edges will be positioned correctly through the peaks of the convoluted structure. This preliminary preparation enables automated winding at high speed while maintaining precise edge positioning for proper adhesive application.
Solution Approach 2:
The patent replaces manual mechanical trimming operations with automated cutting mechanisms integrated into the winding apparatus. These automated systems use controlled cutting elements that can precisely sever the media web at the correct positions while the mandrel rotates, eliminating the need for manual intervention and maintaining high productivity.
3Ease of manufacture
If tension control is not adequately managed during winding, then the process is simpler, but the flutes of underlying layers are crushed
Solution Approach 1:
The winding apparatus incorporates feedback control mechanisms that continuously monitor tension in the media web during winding. Based on this feedback, the system automatically adjusts the winding tension to prevent crushing of the flutes in underlying layers while maintaining adequate tension to ensure proper winding. This feedback control enables the system to handle delicate convoluted structures without damage.
Solution Approach 2:
The system uses dynamic tension control where the winding tension is continuously adjusted during the winding process based on the current state of the media pack. The mandrel rotation speed and web feed rate are dynamically coordinated to maintain optimal tension levels that protect the flute structure while ensuring proper winding density and shape.
4Ease of manufacture
If coreless assembly is implemented, then manufacturing cost decreases, but control over media shape during winding becomes more difficult
Solution Approach 1:
The coreless winding system is designed to allow the media web to self-form the desired shape through the winding process itself. The convoluted structure of the media, combined with controlled winding tension and rotation, enables the pack to naturally assume and maintain its intended shape (oval, race-track, or rectangular) without requiring a supporting core. This self-service approach eliminates core materials and assembly steps while maintaining shape control.
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
Enables efficient, automated formation of filter media packs with precise control over shape and tension, reducing manufacturing costs and ensuring proper fit within filter housings, while maintaining the desired shape and preventing unwinding or unraveling.
Implementation Method 1
a winding motor providing a controlled driving torque to the mandrel, to thereby maintain a controlled tension on the web of fluted filter media
Implementation Method 2
applying adhesives or sealants to portions of the media as it is wound into a coil
Data Source
AI summary
A method and apparatus are provided, for forming a filter element including a media pack in the form of a coiled fluted filter media, by winding the web of fluted filter media around a pair of tools of a mandrel. The tools engage the sides of the filter media. The tools define a major to provide the media pack with a oblong or elongated shape. The web may be fed at constant linear speed, and/or a motor may be controlled in a manner to provide constant driving torque to maintain a constant tension on the web. The winding apparatus and methods may include apparatus or methods to modify the feed path of the web to adjust the tension of the web as it is being wound. Further, the coiled media packs can be fixtured to prevent relaxation. A method may form various shaped media packs with the same apparatus.