Filter Element Seal Arrangement Thermal Welding
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Solution Overview
Problem
Existing filter elements face challenges with seal arrangements, particularly with foamed polyurethane (PU) seals that are less suitable for high-temperature environments and have aesthetic issues, while mechanical gasket-based seals are more time-consuming to manufacture and less robust.
Innovation Solution
A filter element with a molded single-structure seal arrangement, comprising a seal and a seal carrier made of different materials, formed using a multi-component injection molding process, and thermally welded to the filter medium pack, providing a robust and cost-effective solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamed polyurethane seal arrangement is used, then the seal arrangement can close the pleats and provide sealing, but the seal arrangement becomes less suitable for high-temperature environments above 80°C
Solution Approach 1:
The patent uses a composite material system consisting of a thermoplastic polymer matrix combined with a sealing component made of temperature-resistant material. The seal arrangement integrates a seal member (such as an O-ring or gasket) made of materials like fluorocarbon rubber or PTFE that can withstand high temperatures, while the thermoplastic housing provides structural support. This composite approach allows the seal arrangement to maintain both sealing effectiveness and temperature resistance.
2Reliability
If mechanical gaskets with multiple components are used, then the seal arrangement becomes more robust and temperature-resistant, but the manufacturing process becomes more time-consuming
Solution Approach 1:
The patent merges multiple sealing components into a single integrated thermally-welded seal arrangement. The seal member is thermally welded directly to the thermoplastic housing, creating a unified structure that eliminates the need for separate mounting operations, adhesives, or mechanical fasteners. This integration maintains the robustness of multi-component designs while significantly reducing manufacturing steps and time.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (such as screwing, clipping, or adhesively bonding separate gasket components) with thermal welding. The thermoplastic housing and seal member are heated and fused together to create a permanent, robust connection. This substitution eliminates complex mechanical fastening systems while maintaining structural integrity and reducing manufacturing complexity.
3Ease of manufacture
If foamed polyurethane seal arrangement is used, then the seal arrangement can be formed by molding technique, but the filter elements do not have an aesthetic appearance
Solution Approach 1:
The patent changes the material parameters by selecting thermoplastic polymers with properties that enable both aesthetic appearance and manufacturability. The thermoplastic housing can be injection-molded with smooth surfaces, precise geometries, and consistent finishes that provide an aesthetic appearance. The material parameters (such as melt flow index, crystallinity, and surface tension) are selected to optimize both visual appearance and molding processability.
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 enhances the robustness and cost-effectiveness of filter elements, improves manufacturing efficiency, and ensures effective sealing across various temperature conditions.
Implementation Method 1
The first axial side of the seal carrier is thermally welded to at least a circumferential portion of the first axial face of the filter medium pack
Data Source
AI summary
A filter element, for placement in a housing of a filter system, includes a filter medium pack and a seal arrangement having a seal and a seal carrier. The filter medium pack includes, for example, a pleated filter medium or a fluted filter medium. The seal carrier includes an axial side coupled to at least a portion of an axial face of the filter medium pack by a thermal welding manufacturing process. The coupling of the seal to the seal carrier is obtainable by manufacturing the seal arrangement with a multi-material injection molding manufacturing process. The present disclosure further relates to a method for manufacturing a filter element, the method including steps of thermal welding and multi-material injection molding.