Overmolded Disc Filter Housing for Uniform Flow and Burst Strength
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Solution Overview
Problem
Conventional disc filters exhibit inadequate flow uniformity, high flow resistance, and insufficient burst strength across a range of fluids with varying flowrates and characteristics, necessitating improvements for optimal performance.
Innovation Solution
A filter design featuring a first and second housing member with specific geometric configurations, including radial sidewalls with axial steps and a rectilinear sidewall, combined with a thermoplastic overmold to create an integral structure that houses a porous filter element, enhancing flow uniformity and burst strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional filter elements are used with standard housing structures, then manufacturing is simple, but flow uniformity is inadequate and flow resistance is too high
Solution Approach 1:
The housing is divided into first and second housing members with distinct geometric features (radial sidewalls with axial steps, rectilinear sidewalls) that segment the flow path to improve flow uniformity while maintaining manufacturability through modular assembly
Solution Approach 2:
Different portions of the housing members have different geometric configurations - the radial sidewalls have axial steps in specific locations while the rectilinear sidewalls have different orientations, creating local variations in flow characteristics to achieve overall flow uniformity
2Device complexity
If conventional filter elements are used with standard housing structures, then device complexity is low, but burst strength is insufficient
Solution Approach 1:
The housing is segmented into multiple members with specific geometric features that distribute mechanical stress more evenly across the structure, increasing burst strength without requiring excessive complexity
Solution Approach 2:
The filter assembly combines different material properties - the housing members provide structural strength while the filter element provides filtration function, creating a composite structure that achieves both strength and functionality
3Ease of manufacture
If conventional filter elements are used, then manufacturing cost is low, but flow resistance is too high across a broad range of fluids
Solution Approach 1:
The housing geometry is designed to dynamically adapt to different flow conditions - the radial and rectilinear sidewalls with axial steps create flow paths that adjust to varying fluid characteristics, maintaining low flow resistance across a broad range of fluids
Solution Approach 2:
The geometric parameters of the housing members (axial step positions, rectilinear sidewall orientations) are optimized to change the flow characteristics dynamically, reducing flow resistance for different fluid types without increasing manufacturing complexity
Data Source
AI summary
The present application is directed to a filter including: a first housing member having a fluid inlet port; a second housing member positioned axially underneath the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold which is molded over the periphery of the housing members sealing the periphery of the housing members together to form an internal volume housing the porous filter element, where the first housing member includes a radial sidewall comprising at least one axial step, and where the second housing member includes a substantially rectilinear radial sidewall