Filter System With Embedded Support Body For Sealing Stability
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Solution Overview
Problem
Existing filter systems for internal combustion engines with star-shaped filter media and elastic sealing bodies face challenges in achieving optimal stability and sealing effectiveness, particularly in maintaining flexibility and vibration stability during operation.
Innovation Solution
Embedding a supporting body with spaced-apart ribs within the elastic casting compound of the end and sealing body enhances the rigidity and dimensional stability of the filter element, ensuring a reliable connection and improved sealing without impairing flexibility, while the ribs' helical curvature and beveled flanks facilitate better flow and distribution of the casting compound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end and sealing body is made entirely of elastic casting compound, then flexibility and sealing effect are maintained, but rigidity and dimensional stability are insufficient
Solution Approach 1:
The end and sealing body is constructed as a composite structure combining elastic casting compound (polyurethane foam) with a supporting body made of rigid material (metal or plastic). This composite approach allows the elastic material to provide sealing flexibility while the rigid supporting body ensures dimensional stability and rigidity, resolving the contradiction between flexibility and structural strength.
Solution Approach 2:
The end and sealing body is divided into two functional segments: an elastic sealing portion made of casting compound for sealing operations, and a rigid supporting body for structural stability. This segmentation allows each portion to optimize its specific function without compromising the other, achieving both flexibility and rigidity in the overall structure.
2Stability of the object's composition
If a supporting body is added to the end and sealing body, then rigidity and dimensional stability are improved, but flexibility and sealing effect may be impaired
Solution Approach 1:
The supporting body is strategically positioned only in specific regions where dimensional stability is needed, while leaving other areas free to deform for sealing operations. The supporting body is designed with localized reinforcement rather than full-coverage rigidity, preserving the elastic deformation capability where sealing is required while providing stability where needed.
Solution Approach 2:
The elastic casting compound acts as a flexible shell or thin film that can deform for sealing while the rigid supporting body provides internal structural stability. This combination allows the outer elastic layer to accommodate sealing movements while the inner rigid structure maintains overall dimensional stability, resolving the contradiction between flexibility and stability.
3Reliability
If the casting compound is filled completely around the support body, then connection reliability is improved, but air pockets may form during manufacturing
Solution Approach 1:
The supporting body is pre-assembled with the filter medium before the elastic casting compound is applied. This preliminary arrangement ensures proper positioning and facilitates complete impregnation of the supporting body by the casting compound, reducing the risk of air pockets while ensuring reliable connection between all components.
Solution Approach 2:
The supporting body is designed with curved or rounded surfaces rather than sharp edges, which facilitates smoother flow of the elastic casting compound around and into the supporting body structure. This curved geometry helps the casting compound penetrate completely without trapping air pockets, while still providing reliable mechanical connection.
4Ease of manufacture
If the ribs are made straight, then manufacturing is simpler, but flow distribution and air pocket prevention are insufficient
Solution Approach 1:
The ribs of the supporting body are designed with curved or helical geometries rather than straight lines. This curved configuration creates more uniform flow paths for the elastic casting compound, improving distribution and preventing air pockets while remaining manufacturable. The curved ribs guide the flowing compound more effectively through the structure.
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 provides enhanced stability and sealing performance, preventing air pockets and ensuring a permanent connection between the filter medium and the support body, resulting in improved filtration and sealing efficiency.
Implementation Method 1
end and sealing body made of an elastic casting compound
Implementation Method 2
the areas between the ribs being able to be flowed through by the potting compound, which is initially flowable during a manufacturing process
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a filter system (10), particularly for an internal combustion engine, comprising a filter element (18) having a filter medium (20) that in particular is folded in a star shape, the filter medium having a coaxial form, and having at least one end and sealing body (22) that is made from an elastic potting compound and is disposed on a front of the filter medium (20). At least part of a support body (40) is embedded in the elastic potting compound of the end and sealing body (22).