Pleated Filter Element Guide Duct With Reinforced Breakthroughs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter elements for ventilation systems face mechanical strength reduction and deformation issues due to breakthroughs in pleated walls and side strips, leading to impaired guiding and centering, as well as costly residue accumulation during punching processes.
Innovation Solution
The filter element incorporates thermally reinforced breakthroughs, where the edge of the breakthroughs is solidified using melted material from the pleated walls or side strips, maintaining mechanical strength and flexibility, and can include a separate metallic reinforcing component for enhanced stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If breakthroughs are introduced by mechanical means (punching), then guide ducts are formed for mechanical coding, but material is removed and mechanical strength of pleated walls is impaired
Solution Approach 1:
The patent replaces mechanical punching with thermal processing. A punch element heats the pleated wall to melting temperature, and the material is then pressed through the punch element to form the guide duct. This thermal-mechanical process substitutes for conventional mechanical punching, allowing guide duct formation without significant material removal or strength impairment.
Solution Approach 2:
The patent changes the physical state of the pleated wall material by heating it to melting temperature during the guide duct formation process. This parameter change (from solid to melted state and back) allows the material to be reshaped without brittle fracture or excessive material removal, preserving mechanical strength while forming the guide duct.
2Ease of manufacture
If breakthroughs are introduced by punching, then guide ducts are created, but residues accumulate and must be disposed of costily
Solution Approach 1:
The patent replaces mechanical punching with a thermal-mechanical process where material is melted and pressed through the punch element. This substitution eliminates the generation of solid residues that would require disposal, as the material is transformed and integrated into the guide duct structure rather than being cut away as waste.
Solution Approach 2:
The patent recovers the material that would otherwise be discarded as residue. By melting the pleated wall material and pressing it through the punch element, the material is reused to form the guide duct walls and reinforcing edges, converting potential waste into functional structure.
3Ease of operation
If breakthroughs are introduced in pleated walls, then guide ducts are formed for centering, but mechanical instability occurs and guiding function is impaired
Solution Approach 1:
The patent uses thermal processing to melt and reshape the pleated wall material around the guide duct opening. This parameter change allows the formation of a reinforcing edge structure that maintains mechanical stability while preserving the guide duct's centering function. The heated material flows to create a strengthened rim around the breakthrough.
Solution Approach 2:
The patent applies local quality enhancement by creating a reinforcing edge specifically at the guide duct opening where mechanical strength is needed most. The thermal-mechanical process concentrates material at the breakthrough edge, providing localized strengthening without affecting the overall flexibility or centering capability of the guide duct.
4Ease of manufacture
If breakthroughs are introduced in pleated walls, then guide ducts are formed, but bending points are created and uniform bending is impaired
Solution Approach 1:
The patent replaces mechanical punching with thermal-mechanical processing, which melts and reshapes material rather than creating sharp discontinuities. This substitution eliminates stress concentration points and geometric deformations that would create bending points, allowing the pleated wall to maintain its flexibility and uniform bending characteristics.
Solution Approach 2:
By heating the material to melting temperature during guide duct formation, the patent creates a transition zone rather than a sharp breakthrough. This parameter change allows the material to flow and bond smoothly, preventing the formation of rigid bending points while maintaining the guide duct's centering function.
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 ensures reliable mechanical coding and deformation of the filter element without significantly impairing mechanical strength, allowing for precise alignment and sealing, while avoiding costly residue issues and maintaining dimensional stability during flexing.
Implementation Method 1
the edge of the breakthroughs is solidified using melted material from the pleated walls or side strips
Implementation Method 2
the edge of the breakthroughs is solidified using melted material
Data Source
AI summary
A filter element for insertion into a housing of a ventilation or air-conditioning system, including a bellows with pleated walls and pleat tips and a front face, which can be faced towards a wall of the housing, wherein a guide duct is allocated to the front face, wherein the guide duct is formed by at least one breakthrough in the pleated walls and/or in a side strip that is hemming the front face, in view of the object to indicate a mechanical coding for a filter element which ensures a unique allocation of a filter element to a housing, wherein the filter element is provided with breakthroughs and wherein the mechanical strength of pleated walls and side strips is impaired as little as possible by the breakthroughs, characterized in that the breakthrough is provided with a reinforcing.