Foldable Filter Frame Sealing for Higher Media Capacity
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Solution Overview
Problem
Existing filter elements face challenges with adhesive attachment to filter media due to the presence of media support structures, leading to potential leak paths and reduced filter media volume, especially in rectangular filter elements.
Innovation Solution
A filter element design featuring a media support member with side support panels and a seal support frame that allows direct adhesive contact with pleat panels, eliminating the need for reservoirs and media support structures, and utilizing foldable frame portions for improved sealing and media capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If media support structure is interposed between the media pack and seal support frame, then the media pack is supported and provided with rigidity, but the adhesive cannot directly contact the filter media in all locations leading to leak paths and weakened attachment
Solution Approach 1:
The media support member is segmented into a modular framework structure with open spaces rather than a continuous solid structure. This segmentation allows the adhesive to access and contact the filter media in multiple locations while still providing structural support where needed.
Solution Approach 2:
The design transitions from a solid two-dimensional support surface to a three-dimensional framework structure. This dimensional change creates pathways for adhesive to reach the media pack at multiple points while maintaining rigidity through the spatial distribution of support elements.
2Ease of manufacture
If reservoir is formed between side panels and media pack for adhesive receipt, then adhesive is contained and cured properly, but the volume of filter media that can be located within a given sized seal support frame is reduced
Solution Approach 1:
The reservoir structure is completely removed from the design. Instead of containing adhesive in a separate reservoir space, the adhesive is applied directly to the interface between the seal support frame and media pack, eliminating the volume loss while maintaining proper adhesive containment through direct contact bonding.
Solution Approach 2:
The adhesive application area is merged with the sealing interface itself. The seal support frame and media pack are positioned in direct contact, and adhesive is applied at this interface, combining the sealing and bonding functions in the same space without requiring additional reservoir volume.
3Strength
If adhesive is applied to secure seal support frame to media pack with media support structure present, then the frame is attached, but the adhesive must flow around portions of the media support structure leading to potential incomplete flow and leak paths
Solution Approach 1:
The media support structure is extracted or removed from between the seal support frame and media pack in the adhesive application zone. This elimination creates a direct, unobstructed path for adhesive flow, ensuring complete coverage and strong attachment without the complexity of navigating around support structure portions.
Data Source
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AI summary
Filter elements and methods of manufacturing filter elements are provided. Examples of filter elements (100) include a media pack (102) and a frame (106) attached thereto. In one example, the frame (106) includes a side panel (164, 166) that is or includes a foldable portion (168, 170). The foldable portion (168, 170) is folded away from the media pack and an adhesive is located therebetween during assembly. In other examples, a media support member (108) is provided that includes at least one side support panel (140, 142) that supports a side of the media pack (102). A portion of the side support member (140, 142) is positioned between adjacent pleat panels of the media pack.