Filter Sealing Compound Casting for Frame Stability
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Solution Overview
Problem
Existing filters face challenges in manufacturing simplicity, cost-effectiveness, and stability, particularly when varying in size, due to the need for separate sealing and low inherent stability of frame materials.
Innovation Solution
A filter design featuring a pleated filter medium with edge strips connected to a frame via casting, using a groove-shaped casting space for a pourable sealing compound, which also serves as a seal, providing inherent stability and automating the gluing process, while minimizing material usage and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is added separately to the frame, then sealing performance is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent combines the sealing function and the frame structure into a single integrated component. The frame is designed with an integrated seal that is formed as part of the frame body during the extrusion process, eliminating the need for separate seal components and assembly steps. This resolves the contradiction by merging two previously separate functions into one component.
Solution Approach 2:
The frame is designed to perform multiple functions simultaneously: it provides structural support, houses the filter element, and creates the sealing connection through its integrated seal design. This multi-functionality eliminates the need for separate sealing components, reducing device complexity while maintaining sealing performance.
2Ease of manufacture
If U-shaped flexible strips are used without edge strips, then manufacturing simplicity is improved, but stability deteriorates
Solution Approach 1:
The patent applies local quality by adding edge strips only at specific locations where structural support is needed, rather than making the entire frame from heavy material. The edge strips are strategically positioned to provide stability to the filter element while maintaining manufacturing simplicity and using minimal material.
Solution Approach 2:
The frame combines different materials or structural elements (the main frame body and the edge strips) to achieve optimal performance. The edge strips provide the necessary stability and structural support, while the main frame body maintains manufacturing simplicity, creating a composite structure that balances both requirements.
3Strength
If metal is used for the frame, then strength is improved, but weight and material cost increase
Solution Approach 1:
The patent applies local quality by using metal only in specific areas where strength is critical (such as the edge strips and load-bearing sections), while other parts of the frame can use lighter materials or simpler constructions. This localized application of strong materials maintains overall frame strength while minimizing weight and material costs.
Solution Approach 2:
The patent optimizes the frame design by changing parameters such as wall thickness, cross-sectional geometry, and material distribution to achieve the required strength with minimal material usage. The extrusion process allows for optimized geometric parameters that provide high strength-to-weight ratio.
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 enables cost-effective and efficient filter manufacturing with improved stability, weight savings, and a secure connection between the filter element and frame, allowing for easy assembly and reduced material costs.
Implementation Method 1
The frame has a groove-shaped and circumferential casting space, which in particular is only open on one side. The potting space serves to accommodate the sealing potting compound. A section of the edge strip, in particular its end, is accommodated in the casting space and surrounded by sealing casting compound.
Implementation Method 2
the sealing compound simultaneously forms the seal surrounding the frame. the seal is not oriented toward the bellows, but rather to seal against a housing that accommodates the filter or toward a filter receptacle that accommodates the filter
Implementation Method 3
a filter element with a filter medium for filtering a fluid flow, in particular an air flow, the filter medium being pleated
Implementation Method 4
the frame has an undercut adjacent to the bottom of the potting space, such that sealing potting compound can also penetrate into the undercut to create a positive connection between sealing potting compound and the frame after the seal -Casting compound has solidified
Data Source
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AI summary
The invention relates to a filter and a filter assembly (1000) with such a filter. The filter (1000) has a filter element (20) with a pleated filter medium (21) for filtering a fluid flow (L), a frame (10) for receiving the filter element (20), and a seal (1) circumferentially surrounding the outside of the frame. According to the invention, the filter element (20) is bonded to the frame (10) by means of a sealing potting compound (2). It was found to be advantageous to provide the filter medium (21) with at least one edge strip (22) and to connect the edge strip (22) and the frame (10) to each other by potting.