Integral Mesh Filter With Uniform Rib Widths
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Solution Overview
Problem
Conventional mesh filters manufactured by injection molding face issues with productivity and cost due to complex molding processes, leading to increased pressure loss and reduced filter performance when the rib width ratio of longitudinal to transverse ribs is uneven, causing variations in opening areas and inadequate filtration of foreign matter.
Innovation Solution
The mesh filter is designed with identical rib widths for both longitudinal and transverse ribs, and identical groove widths, allowing for integral injection molding that maintains consistent opening shapes and sizes, reducing pressure loss and improving filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the rib width ratio of longitudinal to transverse ribs is uneven, then the molding process is simplified, but the opening area becomes uneven causing increased pressure loss and reduced filter performance
Solution Approach 1:
The patent applies parameter changes by establishing specific width ratios between longitudinal and transverse ribs (W1/W2) and between adjacent ribs (W3/W4) to ensure uniform opening areas. By controlling these geometric parameters within defined ranges, the patent achieves both simplified molding processes and consistent filter performance, resolving the contradiction between process simplicity and filtration reliability.
2Adaptability or versatility
If the rib spacing varies between longitudinal and transverse ribs, then the structure is more flexible, but the opening shapes become irregular causing inadequate filtration
Solution Approach 1:
The patent controls the spacing parameters of longitudinal and transverse ribs within specific ranges relative to their widths (e.g., 0.8≤W3/W1≤1.25 and 0.8≤W4/W2≤1.25). This parameter control ensures that opening shapes remain substantially square while allowing structural flexibility, thereby maintaining both manufacturing precision for consistent filtration and adaptability for design variations.
3Manufacturing precision
If insertion molding is used to accommodate mesh members, then the mesh member can be positioned precisely, but manufacturing time increases compared to integral molding
Solution Approach 1:
The patent merges the mesh member positioning function with the integral molding process by incorporating positioning structures directly into the mold cavity. This allows the mesh member to be accurately positioned while eliminating separate insertion steps, thereby achieving both high positioning accuracy and improved productivity through a single integrated molding operation.
4Reliability
If the opening area is reduced to improve filtration, then filter performance increases, but pressure loss increases reducing fluid flow
Solution Approach 1:
The patent optimizes the opening area by controlling rib width ratios and spacing parameters to create uniform openings with optimal dimensions. This parameter optimization ensures sufficient filtration effectiveness while minimizing pressure loss, achieving the right balance between filtering performance and fluid flow efficiency.
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3D
AI summary
[Object] To improve the productivity of a mesh filter and reduce the cost of the mesh filter while maintaining the filter performance. [Solution] A filter unit 4 connecting an inner cylinder 2 (gate connection part) to an outer cylinder 3 includes a plurality of longitudinal ribs formed at regular intervals orthogonally to an X-axis and in parallel with a Y-axis when a virtual plane orthogonal to a central axis 5 of the inner cylinder 2 is assumed to be an X-Y plane, a plurality of transverse ribs formed at regular intervals orthogonally to the longitudinal ribs and in parallel with the X-axis, and a plurality of rectangular openings formed between the longitudinal ribs and the transverse ribs. The longitudinal ribs are formed on one of a front side and a rear side of the filter unit 4 and the transverse ribs are formed on the other of the front side and the rear side of the filter unit 4. By injecting molten resin into to a cavity from a gate opened toward a cavity portion forming the inner cylinder 2, the inner cylinder 2, the outer cylinder 3, and the filter unit 4 are formed integrally, the rib widths of the longitudinal ribs and the transverse ribs are made constant, and the shapes of the plurality of openings are made identical.