Flexible Filter Element With Injection-Molded Plastic Frame
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Solution Overview
Problem
Existing filter elements with injection-molded frames face challenges in flexibility and durability due to rigid or brittle seals, leading to potential leaks and installation issues when bending is required for housing integration.
Innovation Solution
A filter element with an injection-molded frame made of plastics of alternating hardnesses, allowing for flexible bending by using thermoplastic elastomers at designated locations, which are produced through a two-component injection-molding process, enabling non-destructive deformation and improved sealing without additional post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid or brittle seal is used in the injection-molded frame, then the structural strength is improved, but the flexibility and bendability deteriorate, causing installation problems and potential leaks
Solution Approach 1:
The frame is designed with regions of different material properties: rigid plastic regions provide structural strength and sealing, while flexible plastic regions enable bending and deformation during installation. This local differentiation allows the frame to simultaneously achieve both strength and flexibility requirements.
Solution Approach 2:
The frame uses composite plastic materials with different hardness and flexibility characteristics in different regions. The combination of rigid and flexible plastic materials allows the frame to maintain overall structural integrity while enabling localized bending for installation purposes.
2Strength
If the frame material thickness is increased to ensure durability, then the strength is improved, but the flexibility and bendability deteriorate, leading to material breakage during installation
Solution Approach 1:
The frame thickness and material properties are locally optimized: thicker rigid regions provide durability where needed, while thinner flexible regions enable bending without breakage. This local differentiation resolves the contradiction between overall strength and localized flexibility.
Solution Approach 2:
The material parameters (thickness, hardness, flexibility) are varied across different regions of the frame. By changing these parameters locally, the frame achieves both durability in critical areas and flexibility in bending areas, preventing material breakage during installation.
3Reliability
If a continuous frame structure is used, then the sealing performance is improved, but the ability to bend at specific locations deteriorates
Solution Approach 1:
The continuous frame structure incorporates localized flexible regions that allow bending at specific positions while maintaining overall continuity for sealing. The rigid and flexible regions are strategically positioned to enable installation bending without compromising the sealing path.
Solution Approach 2:
The frame transitions from a completely rigid continuous structure to a dynamic structure with controlled flexibility zones. These zones allow the frame to deform during installation and then return to its original shape, maintaining sealing performance while enabling bendability where required.
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 filter element achieves enhanced flexibility and durability, allowing for easy installation into filter housings while maintaining structural integrity and avoiding material breakage, thus preventing leaks and ensuring effective sealing.
Implementation Method 1
the filter element can be bent flexibly at least in part by deforming the filter medium and the frame or frame element
Data Source
AI summary
A filter element to be inserted into a filter housing, has a filter medium with a rim, wherein the rim is connected to an injection-molded frame or at least one injection-molded frame element, providing a flexibly bendable filter element using a frame made of plastic attached by injection molding, wherein the frame or at least one frame element is made of plastics of different hardnesses in alternation in at least one extension direction, such that the filter element can be bent flexibly at least in part by deforming the filter medium and the frame or frame element.