Plastic End Disk With Multi-Planar Lugs for O-Ring Sealing
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Solution Overview
Problem
Existing replaceable filters with plastic end disks for fuel or oil filtration face manufacturing complexities due to the need for precise accommodation of O-rings, making them costly and difficult to produce.
Innovation Solution
A plastic end plate with a chambered O-ring design featuring radially extending lugs on multiple planes, allowing for easier manufacturing through injection molding, and a star-folded bellows with a threaded plate for secure sealing and fluid flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic end disk with O-ring accommodation is used, then sealing capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent transitions from a conventional single-plane O-ring accommodation structure to a multi-planar lug arrangement. The lugs are distributed across multiple planes (first plane and second plane) spaced apart in the axial direction, creating a three-dimensional chambered structure that simplifies injection molding while maintaining effective O-ring sealing.
Solution Approach 2:
The O-ring accommodation structure is segmented into multiple lugs arranged on different planes rather than a single continuous groove. This segmentation into discrete lugs (at least two on the first plane and at least two on the second plane) facilitates easier manufacturing through injection molding while preserving sealing functionality.
2Reliability
If precise O-ring accommodation is implemented, then sealing performance is improved, but production cost increases
Solution Approach 1:
The multi-planar lug structure is designed to be self-chambering during the injection molding process. The lugs naturally form chambers that accommodate and seal the O-ring without requiring additional machining, assembly steps, or specialized tooling. This self-service design eliminates post-molding operations and reduces production costs while maintaining precise O-ring positioning.
3Ease of manufacture
If lugs are arranged on multiple planes, then manufacturing ease is improved, but structural complexity increases
Solution Approach 1:
The lugs serve multiple functions simultaneously: they provide structural support for the end disk, create chambers for O-ring accommodation, define sealing surfaces, and facilitate injection molding. This multi-functionality reduces the need for separate components or features, simplifying the overall structure despite the multi-planar arrangement.
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 simplifies the manufacturing process of replaceable filters while ensuring effective radial sealing and fluid flow, reducing production costs and enhancing the filter's sealing capabilities without the need for gluing.
Implementation Method 1
the inside of the hollow-cylindrical area is designed for the radial sealing of the plastic end plate on a receiving mandrel by means of an O-ring
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a plastic end disk (100) for a filter element (10), comprising a disk-shaped region (101) for the end-face sealing of a star-pleated bellows (11), a hollow cylindrical region (102) that extends perpendicular to the disk-shaped region (101) in a first direction, wherein the inside (103) of the hollow cylindrical region (102) is formed by an O-ring in order to radially seal the plastic end disk (100) to an accommodating pin and projections (104) extending radially into the hollow cylindrical region (102) for chambering an O-ring are located on the inside (103) of the hollow cylindrical region (102), wherein at least two projections (104) are located on a first plane (105) parallel to the disk-shaped region (101) and at least two projections (104) are located on a second plane (106) spaced from the first plane (105) in the axial direction of the hollow cylindrical region (102), and wherein the projections (104) of the first plane (105) are offset from the projections of the second plane (106) in such a manner that the projections (104) of the first plane (105) projected axially onto the second plane (106) and the projections (104) of the second plane (106) do not overlap in order to enable an undercut-free design of the plastic end disk.