Foamed Elastomer Sealing for Engine Filter Housings
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Solution Overview
Problem
Existing filter elements for internal combustion engines lack a cost-effective and efficient sealing solution that provides a good sealing effect while being flexible and compressible to accommodate varying filter housing configurations.
Innovation Solution
A filter element with a sealing device made from foamed thermoplastic elastomer, injection-molded using a plastics injection molding method, which is flexible and compressible, and can be arranged perpendicularly to the flow direction, providing a secure fit in filter housings and high-volume production capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sealing device is made from solid plastic material, then manufacturing precision and structural stability are improved, but flexibility and compressibility deteriorate
Solution Approach 1:
The sealing device is made from foamed plastic material containing numerous closed-cell bubbles distributed throughout the structure. This porous configuration provides both structural integrity for precise manufacturing and cellular compression capability for flexibility, resolving the contradiction between structural stability and adaptability
Solution Approach 2:
The sealing device combines polymer base material with dispersed bubble structures to create a composite foam material. This composite structure integrates the rigidity needed for manufacturing precision with the compressibility required for flexibility and adaptability to different filter housing configurations
2Reliability
If a custom sealing device is designed for each filter housing configuration, then sealing effect is improved, but device complexity and production cost increase
Solution Approach 1:
The sealing device is designed with dynamic compressibility rather than fixed rigid shapes. The foamed structure allows the same sealing device to adapt its shape and dimensions when compressed, enabling a single design to fit multiple filter housing configurations while maintaining effective sealing
Solution Approach 2:
The foamed sealing device serves multiple functions: it provides sealing against different housing configurations, absorbs manufacturing tolerances, and accommodates various installation positions. This multi-functionality eliminates the need for multiple specialized sealing device variants
3Ease of manufacture
If traditional sealing methods are used, then manufacturing simplicity is maintained, but production volume and cost-effectiveness deteriorate
Solution Approach 1:
The sealing device is integrated directly into the filter element assembly through injection molding, combining what were previously separate manufacturing steps into a single integrated process. This merging enables high-volume production while maintaining manufacturing simplicity through standardized injection molding technology
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 foamed thermoplastic elastomer sealing device ensures a good sealing effect, is cost-effective, and can be compressed to fit various filter housing configurations, enhancing the overall performance and production efficiency of the filter element.
Implementation Method 1
the sealing device is made from a foamed thermoplastic elastomer... the sealing device is very flexible and compressible... When compressing the sealing device, the pores are compressed
Implementation Method 2
the sealing device is very flexible and compressible. This results in a good sealing effect
Data Source
AI summary
A filter element, in particular for filtering the intake air of an internal combustion engine, is provided with a filter medium and a sealing device extending at least partially circumferentially around the filter medium, wherein the sealing device is made from a foamed thermoplastic elastomer, and wherein the sealing device is injection molded using a plastics injection molding method.