Lightweight Plastic Filter Segment with Dovetail Joint
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Solution Overview
Problem
Conventional disc assemblies used for filtering liquid media, particularly in dewatering fiber suspensions, are heavy and difficult to manufacture due to their construction materials and assembly processes.
Innovation Solution
A disc assembly composed of an isosceles trapezoid frame with corrugated clamp lists and wire mesh supported by ribs, made from lightweight plastic materials, allowing for easier assembly and manufacturing through a design featuring self-tapping screws and a dovetail joint for attaching frames of varying sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional disc assemblies are constructed with heavy materials, then structural strength and stability are improved, but weight increases and ease of manufacture deteriorates
Solution Approach 1:
The disc assembly is divided into multiple segments that can be manufactured separately and then assembled together. Each segment is a lighter component that can be produced using standard manufacturing processes, and the modular design allows for easy assembly while maintaining overall structural integrity through the connection of segments.
Solution Approach 2:
The disc assembly uses composite construction combining plastic frame members with wire mesh filtering elements. The plastic frame provides structural support with reduced weight compared to traditional solid materials, while the wire mesh provides the necessary filtering function. This composite approach optimizes both weight and strength.
2Stability of the object's composition
If conventional disc assemblies use complex construction methods, then structural integrity is improved, but ease of manufacture deteriorates
Solution Approach 1:
By segmenting the disc assembly into separate frame members and filtering elements, each component can be manufactured independently using simple processes. The frame segments are produced as separate plastic parts and the wire mesh is formed separately, then assembled together, simplifying manufacturing while maintaining structural integrity through proper connection design.
Solution Approach 2:
The frame members are designed as thin-walled plastic structures that provide sufficient structural integrity through optimized geometry rather than thick, heavy walls. The thin-walled design reduces manufacturing complexity and material usage while maintaining the necessary strength and stability through careful structural configuration.
3Reliability
If conventional disc assemblies are made with heavy materials, then durability is improved, but productivity deteriorates due to easier assembly
Solution Approach 1:
The modular segmented design allows for rapid assembly by simply connecting pre-manufactured segments together, significantly improving assembly productivity. The standardized connection interfaces enable quick assembly operations while the segments themselves are designed to be durable through their optimized plastic construction and proper connection methodology.
Solution Approach 2:
The design changes the material parameter from heavy traditional materials to lightweight plastic, which improves assembly productivity by reducing handling and assembly complexity. The plastic material is selected to maintain durability and reliability through appropriate material selection and structural design, achieving both productivity improvement and maintained durability.
Data Source
AI summary
A disc segment adapted to be attached to other disc segments to form a disc assembly, the disc segment being in the form of a frame, the frame comprising a left side rail and a right side rail, and a plurality of spaced apart parallel horizontally extending ribs, each disc side including a corrugated wire mesh supported by the frame ribs, the corrugated wire mesh including crisscrossing wire strands, the strands crossing perpendicularly to each other, and the wire strands extend at an angle of 45 degrees relative to its frame rib.