One-Piece Thin-Walled Filter Bag Frame for Automation
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Solution Overview
Problem
Existing pocket filter frames are labor-intensive to assemble, require expensive equipment for automation, and are often designed for single-use due to non-removable attachments, leading to high waste generation and inefficiencies.
Innovation Solution
A filter bag fastening system with an integrated, one-piece thin-walled mask made of thermoplastic or metal, featuring an insertion bevel for easy centering and attachment, allowing for both manual and automated assembly, and enabling reusable components through detachable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-part frames are used with traditional corner connectors and profile technology, then the frame structure is stable and reliable, but the assembly process becomes labor-intensive and difficult to automate
Solution Approach 1:
The patent merges multiple frame parts into a single one-piece injection-molded component. The frame includes integrated side walls, end walls, and corner connectors formed as one continuous structure, eliminating the need for separate corner connectors and multiple assembly steps. This enables full automation while maintaining structural stability.
Solution Approach 2:
The frame is designed with integrated attachment features for filter pockets that are seamlessly incorporated into the one-piece structure. The filter pockets can be individually attached to predetermined locations on the frame, allowing modular assembly while the frame itself remains a single automated component.
2Loss of substance
If cast frames with high-foaming systems are used to save material, then material usage is reduced, but the molds become extremely expensive and require milling from solid
Solution Approach 1:
The patent uses injection molding with controlled foam expansion parameters to achieve complete mold filling without requiring extremely stable molds. The injection molding process allows for controlled material flow and expansion, reducing the need for expensive precision-milled molds while maintaining material efficiency.
3Loss of substance
If high pressures are used in mold curing to save material, then material efficiency improves, but stresses after demolding cause inaccurate external dimensions
Solution Approach 1:
The patent employs controlled pressure parameters during injection molding and demolding at optimized rates to minimize stress and dimensional inaccuracy. The process uses gradual pressure application and release, along with controlled cooling rates, to maintain both material efficiency and dimensional precision.
4Manufacturing precision
If metal profiles are used as corrective measure for stabilization, then dimensional accuracy improves, but the element becomes more difficult to dispose of and cannot be fully incinerated
Solution Approach 1:
The patent achieves dimensional accuracy through optimized injection molding parameters including controlled cooling rates, pressure management, and mold design features. This eliminates the need for metal stabilization profiles, maintaining full incinerability of the plastic frame while achieving required dimensional tolerances.
5Quantity of substance
If foam mass penetrates through the filter medium in the embedding area, then the filter medium appearance becomes uneven, but this creates high potential for customer complaints
Solution Approach 1:
The patent separates the frame structure from the filter medium attachment area. The one-piece frame includes integrated attachment features that secure filter pockets without requiring foam penetration through the filter medium. This eliminates the appearance defects while maintaining secure attachment.
6Reliability
If non-removable attachments are used to secure filter pockets, then the frame and filter pockets form a stable single unit, but the frame concepts are designed for single use only leading to high waste
Solution Approach 1:
The patent uses removable attachment mechanisms such as snap-fit connections, clips, or interchangeable fasteners that allow filter pockets to be securely attached during use and easily removed for replacement. This enables the frame to be reused multiple times while maintaining stable attachment during operation, reducing waste.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a filter bag securing system comprising at least one filter bag (2) which has an opening (5), a receiving body (3) for receiving the at least one filter bag (2), and at least one support body (1), wherein the at least one filter bag (2) is positioned and fixed by means of the receiving body (3) and the support body (1). The receiving body (3) has a border (6) and at least one frame (4), and the contour of the frame (4) is adapted to the contour of the opening (5) of the at least one filter bag (2). According to the invention, the receiving body (3) is a single-part thin-walled mask (3), and the at least one frame (4) tapers away from the border (6).