Plastic Frame Injection Molding for Cabin Filter Profile Stability
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Solution Overview
Problem
Existing filter elements for motor vehicles, such as cabin air filters, face challenges in maintaining fold profiles and achieving effective sealing without the need for additional bonding or specialized manufacturing processes.
Innovation Solution
A filter element with a plastic frame injected onto the fold pack and a plastic foam seal foamed onto the frame, produced through injection molding, which provides stability and sealing without the need for separate side bands or additional bonding, allowing for adaptable geometry and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If side bands made of filter fleece material are glued to the fold profiles for stabilization and sealing, then the fold profiles are stabilized and sealing is provided, but additional bonding processes and separate components are required
Solution Approach 1:
The plastic frame combines multiple functions into a single integrated component: it provides fold profile stabilization through its rigid structure, creates sealing surfaces through its geometry, and eliminates the need for separate side bands and bonding processes. The frame is molded as one piece that directly contacts and stabilizes the fold profiles while providing sealing edges.
Solution Approach 2:
The plastic frame serves multiple functions simultaneously: structural support for the fold profiles, sealing element against the housing, and replacement for the previously separate side bands. This multi-functional design reduces the number of components and manufacturing steps while achieving the same technical effects.
2Reliability
If foam is applied to the edges for sealing and fold support, then sealing is achieved, but the sealing foam lip could only be attached to special places due to manufacturing process constraints
Solution Approach 1:
The sealing function is merged with the frame structure itself. The plastic frame includes integrated sealing edges and surfaces that are part of the frame geometry, eliminating the need for separate foam applications. The frame is designed with specific geometric features that create sealing contact with the housing.
Solution Approach 2:
The sealing approach changes from applying a separate soft foam material to using the rigid plastic frame's geometric parameters and surface characteristics. The frame's edge geometry, contact surfaces, and positioning are optimized to create effective sealing through its structural design rather than through material compliance.
3Productivity
If a plastic frame is injected onto the fold pack for support and sealing, then manufacturing complexity is reduced and production becomes more efficient, but the frame must provide both structural support and sealing functions
Solution Approach 1:
The frame design merges structural support and sealing functions into a single molded component. The injection molding process creates a frame with integrated features: rigid sections for fold profile support and geometric sealing surfaces for housing contact. This single-component design eliminates assembly steps while achieving both functions.
Solution Approach 2:
The frame's physical parameters are optimized during molding to achieve both functions: thickness and rigidity in support areas, and specific geometric profiles in sealing areas. The material properties and geometric parameters are selected to provide structural integrity while creating effective sealing surfaces through the molding process itself.
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
This solution achieves stable fold profile support and secure sealing while reducing manufacturing complexity and costs, enabling quick and cost-effective production of filter elements with customizable geometry and improved mechanical properties.
Implementation Method 1
a plastic frame that is at least partially injected onto the fold pack
Implementation Method 2
a plastic foam seal that is at least partially foamed onto the plastic frame
Data Source
Figure 1~3D
Figure 4A~4B
Figure 5A~5F
AI summary
The invention relates to a filter element (1), for example a cabin filter for a motor vehicle, comprising a pleated structure (2), a plastic frame (4) that is molded at least in part to the pleated structure (2) for supporting pleat profiles (3) of the pleated structure (2), and a plastic foam seal (7) that is foamed at least in part to the plastic frame (4). In a method for producing a corresponding filter element (1), a plastic frame (4) is generated at least in part around a pleated structure (2) in a first injection molding process, and subsequently a plastic foam seal (7) is generated at least in part on the plastic frame (4) in a second injection molding process.