Fluted Filter Frame Attachment via Plastic Welding and Adhesive Beads
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Solution Overview
Problem
Existing filter elements with fluted media face challenges in secure attachment to frames and effective sealing, leading to potential clogging and inefficient filtration due to inadequate attachment methods and sealing mechanisms.
Innovation Solution
The use of plastic welding to secure a fluted filter media pack to a frame, with a border frame providing structural support and an annular seal for effective sealing, and a method involving adhesive beads for secure attachment, ensuring proper alignment and sealing between the filter media pack and the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods are used for filter elements, then the structure is simpler, but the sealing effectiveness is insufficient leading to potential clogging
Solution Approach 1:
The sealing structure is segmented into multiple independent seals positioned at different locations within the filter element. This includes seals at the inlet end, outlet end, and intermediate positions, allowing each seal to address specific sealing needs independently, thereby improving overall sealing effectiveness without requiring a completely complex integrated structure
Solution Approach 2:
The sealing structures are pre-configured and pre-positioned during filter element assembly before installation in the housing. The seals are预先 arranged to ensure proper contact and sealing engagement, eliminating the need for complex adjustment mechanisms during operation while maintaining reliable sealing
2Ease of operation
If clearance gap is provided for removal, then ease of removal is improved, but sealing reliability deteriorates due to potential short circuiting
Solution Approach 1:
The sealing structures utilize flexible sealing elements that can deform and adapt to the housing surface. These flexible seals maintain continuous contact with the housing even when the filter element is installed with clearance gaps, preventing fluid short circuiting while allowing easy removal without compromising sealing integrity
3Reliability
If multiple seals are added for better sealing, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
Multiple sealing functions are merged into integrated seal assemblies that combine multiple sealing elements into unified structures. These merged seal assemblies perform multiple sealing tasks simultaneously at different locations, improving sealing effectiveness without proportionally increasing the number of separate components or assembly steps
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
This solution enhances the secure attachment and sealing of filter elements, preventing clogging and ensuring efficient filtration by providing a robust and reliable interface between the filter media and the frame, improving handling and installation resilience.
Implementation Method 1
laying an adhesive bead around the annular wall in spaced relation from the seat, and inserting the filter media pack into the annular wall toward the seat and engaging the adhesive bead causing the adhesive bead to shear along the annular wall in a continuous ring toward the seat
Implementation Method 2
The frame in this embodiment is formed at least in part from plastic material such that the outer wrap or wraps or outer side of the filter media pack is welded to the plastic portion of the frame using a suitable plastic welding process
Data Source
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AI summary
A filter element includes a filter media pack, a frame, an annular seal, and a sealing means independent of the annular seal, attaching the filter media pack and the frame. The means of sealing an interface between the filter media pack and the frame include molding a filter media pack seal, plastic welding outer wraps of filter media pack to the frame, and securing the filter media pack and the frame using a bead of adhesive.