Multiple-Wound Yarn Filter Element for Zigzag Fold Stability
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Solution Overview
Problem
Existing filter elements for motor vehicles require complex and costly manufacturing processes to stabilize zigzag-shaped folds, often involving hot-melt adhesive threads that require additional force and resources for application.
Innovation Solution
A filter element using multiple-wound yarns with fibers that are coated with adhesive material, allowing for better absorption and reduced force required during attachment to fold edges, forming a shape-stable grid structure that simplifies the manufacturing process and enhances stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If hot-melt adhesive threads are used to stabilize folded filter media, then fold stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the adhesive material by using reactive adhesives that cure through chemical reaction rather than thermal adhesives that require heat maintenance. This allows the adhesive to remain in an applied state during manufacturing and then transform into a stable bonded state, simplifying the manufacturing process while maintaining fold stability.
Solution Approach 2:
The patent extracts the stabilization function from the adhesive application process itself by using reactive adhesives that cure after application. This eliminates the need for separate thermal processing equipment and complex temperature control systems, reducing manufacturing complexity while maintaining the stabilizing effect on folds.
2Strength
If hot-melt adhesive is used to attach threads to fold edges, then attachment strength is improved, but additional force and resources are required during application
Solution Approach 1:
The patent replaces the thermal-mechanical system of hot-melt adhesive application with a chemical system. Instead of using heat and pressure to maintain adhesive in a plastic state and then cooling it to set, the invention uses reactive adhesives that form chemical bonds at ambient or moderate temperatures, eliminating the need for thermal energy input during the bonding process.
Solution Approach 2:
The patent changes the bonding mechanism from physical (thermal) to chemical (reactive). The adhesive material transitions from requiring thermal energy to achieve bonding to requiring only chemical reaction conditions, significantly reducing energy consumption during the attachment process while maintaining or improving attachment strength.
3Strength
If conventional yarns with twisted or wound-together filaments are used, then thread strength is improved, but adhesive absorption and distribution are worsened
Solution Approach 1:
The patent segments the yarn structure into individual filaments that are not tightly twisted or wound together. This segmentation creates spaces between filaments that allow adhesive material to penetrate and distribute throughout the yarn structure, improving adhesive absorption and bonding effectiveness while maintaining the inherent strength of the filament material.
Solution Approach 2:
The patent creates local quality variations in the yarn structure by using loose, segmented filaments rather than uniform tight twists. This allows adhesive to be absorbed and distributed locally throughout the yarn volume, ensuring comprehensive bonding coverage while maintaining the overall structural integrity and strength of the thread.
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 use of multiple-wound yarns with adhesive material results in a more efficient and cost-effective manufacturing method, providing improved stability and uniform distribution of the thread on fold edges, reducing material expenditure while maintaining effective filtration performance.
Implementation Method 1
a thread that is coated with a hot-melt adhesive is wrapped around a cylinder-shaped filter element
Data Source
AI summary
A filter element for filtering a fluid has a zigzag-shaped folded filter medium with fold edges neighboring each other. A thread is attached by an adhesive material to the fold edges. The thread is a multiple-wound yarn. In a method for manufacturing the filter element, a thread in the form of a multiple-wound yarn is attached by an adhesive material to fold edges of a zigzag-shaped folded filter material. In the method, the thread is soaked and/or coated with the adhesive material that is in a plastic state. The thread soaked and/or coated with the adhesive material is attached to the fold edges by applying a pressure, and the adhesive material is hardened.