Foamed Polyurethane Overmold Seal for Filter Element
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Solution Overview
Problem
Existing air cleaners for engines and power generation systems face challenges in effectively filtering out contaminants from air streams due to inefficiencies in seal arrangements and media pack configurations, leading to suboptimal performance and maintenance issues.
Innovation Solution
A filter element or cartridge with a coiled z-filter media pack and an integral overmold seal arrangement, featuring a preform and molded seal component made from foamed polyurethane, which provides a robust seal between the filter and the air cleaner, enhancing air filtration efficiency and ease of serviceability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional seal arrangements are used in filter elements, then manufacturing is simpler, but sealing effectiveness and filtration performance deteriorate
Solution Approach 1:
The patent combines the preform and overmold into an integrated seal arrangement where the overmold is formed directly on the preform structure. This merging of components creates a unified sealing system that improves sealing effectiveness while avoiding the complexity of assembling multiple separate seal parts.
Solution Approach 2:
The seal arrangement uses composite construction with a preform base structure and an overmold layer formed from seal material. This composite approach allows each material to contribute its optimal properties - the preform provides structural support while the overmold provides sealing functionality, achieving reliable sealing without excessive complexity.
2Ease of repair
If serviceable filter elements are used, then maintenance ease improves, but seal reliability during operation deteriorates
Solution Approach 1:
The filter element is designed with separable components - the media pack can be removed and replaced while the preform and overmold seal arrangement remains in the air cleaner. This segmentation enables easy serviceability as the media pack can be quickly exchanged without removing the entire filter assembly, while the permanent preform-overmold structure maintains seal reliability during operation.
Solution Approach 2:
The preform acts as an intermediary component that remains permanently installed in the air cleaner housing, providing a stable mounting structure and seal interface. The removable media pack interfaces with this permanent preform structure, allowing easy replacement while the preform-overmold combination maintains consistent seal integrity across multiple service cycles.
3Productivity
If inlet flutes are closed near outlet end and outlet flutes closed near inlet end, then filtration efficiency improves, but manufacturing precision requirements worsen
Solution Approach 1:
The patent applies different closure characteristics to different locations of the flutes - inlet flutes are closed near the outlet end while outlet flutes are closed near the inlet end. This local differentiation of closure positioning optimizes filtration efficiency by ensuring proper flow direction and pressure differential across the media pack, while the preform structure provides a rigid framework that maintains these precise local closure characteristics during assembly and operation.
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 improves air filtration efficiency by ensuring effective sealing and easy replacement of filter elements, reducing contamination and maintenance costs while maintaining filter performance over time.
Implementation Method 1
the overmold comprises foamed polyurethane
Data Source
AI summary
A filter element arrangement is provided which includes a media pack comprising Z-filter media, a preform and an overmold sealing a portion of the interface between the preform and the media pack, and also forming an air cleaner seal for the filter element. The overmold preferably comprises molded, foamed, polyurethane. A variety of media pack shapes can be used.