Injection Molded Mesh Filter with Uniform Rib Structure
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Solution Overview
Problem
Conventional mesh filters manufactured by insertion molding require increased man-hours and have higher product costs due to complex molding processes, while those produced by injection molding face issues with pressure loss and filter performance due to uneven rib widths and opening areas.
Innovation Solution
A mesh filter designed for injection molding with a disc-shaped gate connection part, an outer cylinder, and a filter unit featuring evenly spaced longitudinal and transverse ribs, ensuring uniform rib widths and identical opening shapes, allowing for a one-piece construction that improves productivity and reduces costs while maintaining filter performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insertion molding is used to manufacture mesh filters, then the filter structure can accommodate mesh members, but manufacturing man-hours increase and productivity decreases
Solution Approach 1:
The invention merges the mesh member and frame body into a single integrated component formed by injection molding. The mesh member is embedded within the frame body during the molding process, eliminating the need for separate assembly steps while maintaining the structural integrity and filtering functionality of the mesh filter.
2Productivity
If injection molding is used with uneven rib widths, then productivity improves, but opening area decreases and pressure loss increases
Solution Approach 1:
The invention applies local quality by making the rib widths uniform throughout the frame body structure. This ensures consistent opening areas between mesh members, optimizing fluid flow characteristics and minimizing pressure loss while maintaining the benefits of injection molding productivity.
3Ease of manufacture
If injection molding is used with variable rib spacing, then manufacturing is simplified, but opening shape consistency deteriorates and filter performance decreases
Solution Approach 1:
The invention maintains constant rib spacing and uniform rib dimensions as key parameters throughout the frame body. This ensures that all openings between mesh members have identical shapes and sizes, guaranteeing consistent filter performance while remaining compatible with injection molding manufacturing processes.
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 enables the integration of mesh filters through injection molding, reducing production time and costs while ensuring consistent filter performance by maintaining uniform rib widths and opening shapes, effectively filtering out foreign matter without compromising pressure loss or filter efficiency.
Implementation Method 1
the entire body is integrally molded by injection molding
Implementation Method 2
filter out foreign matter in fluid such as fuel or oil using the mesh filter
Data Source
AI summary
A filter unit connecting a gate connection part to an outer cylinder includes a plurality of longitudinal ribs formed at regular intervals orthogonally to an X axis and parallel to a Y axis when a virtual plane orthogonal to a central axis of the gate connection part is assumed to be an X-Y plane. A plurality of transverse ribs is formed at regular intervals orthogonally to the longitudinal ribs and parallel to the X axis, and a plurality of rectangular openings is formed between the longitudinal ribs and the transverse ribs. By injecting molten resin into a cavity from a gate opened toward a cavity portion forming the gate connection part, the gate connection part, the outer cylinder, and the filter unit 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.