RO Filter Housing Composite Overwrap and Segmented Liner
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Solution Overview
Problem
Conventional reverse osmosis filter cartridge housings are either expensive and heavy (made of steel) or complex and difficult to customize (made of composite glass fiber-reinforced plastics).
Innovation Solution
A housing for reverse osmosis filter cartridges made of a hollow cylindrical thermoplastic polymer liner with a fiber-reinforced polymer head assembly and an overwrap layer of wound filaments and polymeric resin, which is lightweight, strong, and easily customizable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel is used for housing, then strength and pressure resistance are improved, but weight and cost increase
Solution Approach 1:
The housing uses a composite structure combining a thermoplastic polymer liner with an overwrap layer of wound filaments (such as fiberglass or carbon fiber) and polymeric resin. This composite construction provides steel-level strength and pressure resistance while significantly reducing weight, as the high-strength filaments bear the mechanical loads while the polymer matrix binds them together.
Solution Approach 2:
The housing applies different materials to different regions based on local requirements: the thermoplastic liner provides chemical resistance and seals the internal environment, while the overwrap layer of wound filaments is strategically applied to areas requiring high strength and pressure resistance, optimizing the weight-strength balance by concentrating reinforcement where most needed.
2Weight of moving object
If composite glass fiber-reinforced plastics are used for housing, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The housing is divided into two distinct components: a thermoplastic polymer liner and an overwrap layer of wound filaments. The liner can be manufactured separately using injection molding or extrusion processes, then the overwrap layer is applied in subsequent steps. This segmentation allows each component to be optimized and manufactured independently using different processes, reducing overall manufacturing complexity.
Solution Approach 2:
The invention transitions from traditional composite manufacturing (which requires complex moldings and curing cycles) to a two-stage process: first forming the thermoplastic liner using standard plastic processing, then applying the overwrap layer of wound filaments with polymeric resin. This parameter change in manufacturing approach simplifies production while maintaining weight advantages.
3Weight of moving object
If conventional composite housings are used, then weight is reduced, but adaptability and customization capability deteriorate
Solution Approach 1:
By separating the housing into a liner and an overwrap layer, the design allows independent customization of each component. The liner can be modified for different chemical resistances or sealing requirements, while the overwrap layer can be adjusted in thickness, filament type, and winding pattern to meet specific strength and pressure requirements, enabling rapid adaptation to different applications.
Solution Approach 2:
The overwrap layer can be selectively applied with varying filament orientations, densities, and material compositions to different sections of the housing based on specific structural requirements. This localized customization allows the housing to be adapted for different pressure zones, mounting configurations, or application-specific demands without redesigning the entire structure.
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 provides a lightweight, strong, and easily customizable housing that can withstand substantial internal pressures while being cost-effective and simple to manufacture, addressing the drawbacks of existing materials and manufacturing complexities.
Implementation Method 1
an overwrap layer comprising wound filaments and a polymeric resin, which covers the outer surface of the liner and the outer side of the head assembly
Implementation Method 2
a hollow head assembly. The head assembly comprises a collar portion formed of a thermoplastic polymer and a barrel portion formed of a fiber-reinforced polymer
Implementation Method 3
A connecting portion of the collar portion is joined to the liner at the first open end (e.g., by spin welding)
Data Source
AI summary
Housings for reverse osmosis filter cartridges and methods of making the same. The housings include: (1) a hollow cylindrical liner formed of a thermoplastic polymer that is adapted to surround a reverse osmosis filter cartridge; (2) a hollow head assembly that includes a transition collar portion formed of a thermoplastic polymer that is joined to said liner and a barrel portion formed of a chopped glass fiber-filled polymer that is overmolded onto said transition collar portion; (3) an end plug that is adapted to be received within an opening in the barrel portion; and (4) an overwrap layer comprising wound glass filaments and a polymeric resin that covers the outer surfaces of the liner and head assembly.