Modular Filter Core Assembly for Uniform Edges and Variable Length
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Solution Overview
Problem
Existing modular filter cores have limitations in length adjustment, often requiring additional components like end caps and resulting in non-uniform edges due to male and female component exposures, which can lead to structural issues and inefficiencies.
Innovation Solution
A modular filter core design featuring male and neutral ends with extensions that can engage with either type, allowing for variable length assembly without additional components, ensuring a uniform external surface and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If male and female components are used to create modular filter cores, then the filter core can be assembled in discrete lengths, but the edges become non-uniform and exposed surfaces create structural issues
Solution Approach 1:
The filter core segments are designed with both male and female engagement features, allowing any segment to connect to any other segment regardless of orientation. This universal connectivity enables the formation of filter cores of various lengths while maintaining uniform edges, as each connection point presents the same external appearance regardless of which segments are joined together.
2Shape
If end caps are added to reduce exposure of male and female ends, then edge uniformity is improved, but the device complexity and assembly requirements increase
Solution Approach 1:
The male and female engagement features are integrated directly into the filter core segments themselves, eliminating the need for separate end cap components. The segments are designed so that their external surfaces appear uniform at all connection points, merging the function of edge coverage into the segment design rather than requiring additional protective caps.
3Adaptability or versatility
If filter cores are cut and welded to create desired lengths, then custom lengths are achieved, but manufacturing precision and structural integrity are compromised
Solution Approach 1:
The filter core is divided into standardized modular segments with predetermined lengths and standardized engagement features. To create custom lengths, these pre-fabricated segments are connected through their male-female features rather than cutting and welding a single piece. This segmentation approach maintains manufacturing precision by using factory-produced standardized units while enabling length customization through modular assembly.
Data Source
AI summary
A filter core segment for use in forming a filter core is provided herein. The filter core segment comprises a male end comprising a male rib defining an outer surface and an opposite inner surface. The male end further comprises an inner support disposed radially inward from an inner surface of the male rib. The male end further comprises a first and second extension each comprising a neck extending from the inner surface of the male rib and a head attached thereto. The filter core segment further comprises a neutral end opposite the male end, and a plurality of columns extending therebetween. The filter core segment further comprises a plurality of ribs extending about the plurality of columns. The first and second extension are configured to engage a male end or a neutral end of an adjacent filter core segment to form the filter core.