Rotating Melt Filter with Integrated Exchange Station
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Solution Overview
Problem
Existing melt filters are inefficient due to large and expensive filter disks, inadequate surface area for filtration, pressure differences during filter element exchange, and exposure to ambient air leading to unwanted plastic changes and high manufacturing costs.
Innovation Solution
A compact melt filter design with a completely covered filter disk and a larger-than-one-but-smaller-than-two-filter-elements filter-element-changing station, utilizing a reversible movable region to maintain constant pressure and prevent plastic exposure to air, with optimized angular spacing and spoke dimensions to maximize filtration surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filter disk is made large to provide sufficient filtration surface area, then the filtration efficiency improves, but the device size and manufacturing cost increase significantly
Solution Approach 1:
The patent transitions from a single-plane filtration approach to a three-dimensional configuration where the melt passage widens toward the filter elements, allowing the melt to flow against multiple filter elements simultaneously in different spatial zones. This dimensional change enables sufficient total filtration surface area within a compact filter disk footprint.
Solution Approach 2:
The filter disk is designed to perform multiple functions: it provides the filtration surface, supports exchangeable filter elements, and incorporates a integrated changing station that allows filter element replacement without removing the entire filter disk assembly. This multi-functionality reduces the need for additional components and space.
2Ease of repair
If the filter-element-changing station is made large to accommodate filter element exchange, then the ease of maintenance improves, but the device complexity and cost increase
Solution Approach 1:
The filter-element-changing station is designed as a compact, nested structure that fits within the existing housing space. The station incorporates integrated components where the cover, locking mechanisms, and filter element handling features are nested within each other, maximizing functionality within minimal space.
Solution Approach 2:
The filter element changing station is designed to be operable without specialized tools or complex procedures. The cover can be opened, filter elements exchanged, and the station closed using simple manual operations, making the maintenance process self-serviceable and reducing the need for complex mechanical assistance systems.
3Productivity
If the melt passage is widened toward the filter elements to allow flow against multiple filter elements, then the filtration capacity improves, but the pressure distribution becomes uneven
Solution Approach 1:
The melt passage is designed with varying cross-sectional dimensions along its length, creating different flow characteristics in different zones. The passage widens toward the filter elements to increase filtration capacity while the local geometry is optimized to distribute melt flow evenly across all filter element surfaces, preventing pressure hotspots and ensuring uniform pressure distribution.
4Object-affected harmful factors
If the filter disk is completely covered during operation to prevent plastic exposure to air, then the plastic quality is maintained, but the device complexity increases
Solution Approach 1:
The cover for the filter disk is merged with the housing structure and the filter-element-changing station components. The cover is integrated into the existing mechanical framework, serving both as a protective enclosure and as part of the filter element changing mechanism, thereby preventing plastic exposure to air without adding separate complex cover mechanisms.
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 allows for higher pressures, prevents plastic changes during filtration, ensures constant pressure during filter element exchange, and reduces manufacturing costs while maintaining a compact and efficient filtration surface.
Implementation Method 1
a filter disk (3) with spokes (11) and with filter elements (8) arranged in a circularly annular array, which are supported by perforated support disks (15)
Implementation Method 2
a power-driven ratchet drive (4) for rotationally stepping the filter disk (3)
Implementation Method 3
the plates (5, 5') enclose the filter disk (3) between them, and the filter disk (3) is braced against a perforated support disk (15)
Data Source
AI summary
A melt filter for cleaning a plastic melt issuing from an extruder has a wheel rotatable about an axis and having an outer rim and a plurality of spokes forming an annular array of axially open spaces, a pair of housing plates axially sandwiching and completely covering the wheel and forming offset from the axis a melt passage extending axially through the wheel at the spaces, and removable filter elements braced axially against the wheel at the spaces between the spokes and angularly movable with the wheel with the melt flowing through the filter elements when same are aligned with the passage. One of the plates being formed with an edge cutout. A part on the one housing plate that can cover and close the cutout during normal operation of the melt filter can open and uncover the cutout for changing the filter element aligned axially with the cutout.