Fluted Filter Axial Seal With Dual-Durometer Composite
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Solution Overview
Problem
Existing filter elements with fluted media packs face challenges in maintaining effective seals and structural support within filter housings, leading to potential bypass of unfiltered fluids and difficulty in removal and replacement.
Innovation Solution
The filter element incorporates a fluted filter media pack with an axial seal member and a media pack seal member, where the axial seal member is formed of a softer polymeric material and the media pack seal member of a rigid polymeric material, both molded independently or in a single mold cavity, to provide a secure axial seal and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single seal member is used for both axial sealing and media pack sealing, then device complexity is reduced, but sealing reliability deteriorates due to inability to provide different sealing characteristics for different sealing surfaces
Solution Approach 1:
The seal member is divided into two distinct sealing portions: a first sealing portion for axial sealing against the filter housing and a second sealing portion for sealing against the media pack. Each portion can be made from different polymeric materials with different durometer values, allowing optimization of sealing characteristics for each specific sealing surface while maintaining separate functional zones within a single integrated component.
Solution Approach 2:
The seal member is constructed as a composite structure with at least two different polymeric materials having different durometer values. The harder polymeric material provides structural support and resists compression deformation, while the softer polymeric material provides superior sealing contact and conforms to mating surfaces, achieving reliable sealing across both interfaces.
2Strength
If a harder polymeric material is used for the axial seal member, then structural support is improved, but sealing effectiveness against the filter housing deteriorates
Solution Approach 1:
Different regions of the seal member are assigned different material properties: the first sealing portion contacting the filter housing is made from a softer polymeric material optimized for sealing conformity and contact, while the second sealing portion contacting the media pack is made from a harder polymeric material optimized for structural support and resistance to compression deformation.
Solution Approach 2:
The seal member combines polymeric materials with different durometer values in a single integrated structure. The softer material in the first sealing portion ensures effective sealing against the filter housing, while the harder material in the second sealing portion provides the necessary structural support and dimensional stability.
3Adaptability or versatility
If the seal member is molded in multiple separate molds, then material selection flexibility is improved, but manufacturing complexity and time increase
Solution Approach 1:
The seal member is molded as a single integrated component in one molding operation, combining the first sealing portion and second sealing portion into one piece. This allows different polymeric materials to be co-molded or overmolded in a single process, achieving material versatility without requiring multiple separate molding operations, thereby reducing manufacturing complexity and cycle time.
Solution Approach 2:
The molding process is designed to accommodate multiple polymeric materials with different durometer values in a single mold cavity. Through techniques such as two-shot molding, insert molding, or co-molding, the seal member is formed as one integrated part containing different materials in different regions, achieving both material flexibility and manufacturing efficiency.
Data Source
Figure 1~2A
Figure 3
Figure 4~5A
AI summary
A filter element includes a filter media pack and an axial seal member configured to axially seal against a filter housing. The axial seal member may be supported by and attached to the filter media pack by a media pack seal member. Alternatively, the axial seal member may be carried by a frame, which is attached to the filter media pack by the media pack seal member.