Spiral-Wound Filter Element with Mesh Support for Oil Mist
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Solution Overview
Problem
Existing filter elements for capturing oil mist in compressed air face challenges such as increased manufacturing costs due to complex construction methods, potential damage to filtration materials, and reduced air flow rates caused by thick non-woven fabric layers or accumulation of oil mist, leading to blocked gas flow.
Innovation Solution
A filter element formed by spirally winding a plastic mesh-like member and filtration material, with the mesh-like member providing structural support and protection to the filtration material, allowing for easier manufacturing and maintaining air flow without the need for additional protective layers or complex welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a plate material is cut and welded to form a reinforcing cylinder, then the filter element gains structural strength, but the manufacturing process becomes complex and costly
Solution Approach 1:
The invention removes the reinforcing cylinder component entirely from the filter element structure. Instead of using a separate metal cylinder that requires cutting and welding, the filter element relies on the inherent strength of the filtration material and its support structure, eliminating the complex metalworking operations while maintaining sufficient structural integrity for the application.
Solution Approach 2:
The invention integrates the support function into the filter element structure itself rather than using a separate reinforcing cylinder. The support structure is combined with the filtration material in a unified design that eliminates the need for additional components and assembly steps like welding.
2Reliability
If a non-woven fabric protective layer is added between the filtration material and reinforcing cylinder, then the filtration material is protected from damage, but the number of components and manufacturing steps increases
Solution Approach 1:
The invention removes the separate non-woven fabric protective layer from the filter element construction. The design uses a support structure that inherently protects the filtration material without requiring an additional protective layer, thereby reducing the total number of components and simplifying the manufacturing process.
3Strength
If a thick layer of non-woven fabric is used to ensure strength, then the filter element gains structural integrity, but air flow is blocked and pressure drops
Solution Approach 1:
The invention applies support structures only where structurally necessary rather than using a thick uniform layer of non-woven fabric throughout. This localized approach provides sufficient structural integrity at critical points while maintaining open air flow paths in the filtration regions, preventing pressure drops and maintaining productivity.
4Manufacturing precision
If precise size management of plate material and jacket is implemented, then foreign matter capture at axial ends is improved, but manufacturing costs increase
Solution Approach 1:
The invention eliminates the separate jacket component that requires precise size matching with the plate material. By removing this component, the need for tight dimensional tolerances and precise size management is eliminated, reducing manufacturing complexity and cost while still achieving effective foreign matter capture at the axial ends through the filter element design 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 configuration simplifies the manufacturing process, reduces costs, ensures proper strength without blocking air flow, and allows for effective capture and precipitation of oil mist, maintaining air flow rates and preventing clogging.
Implementation Method 1
a filtration material for capturing oil mist in the gas passing through the filter element
Implementation Method 2
a plastic mesh-like member... the mesh-like member providing structural support and protection to the filtration material
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A filter element (13) is provided with a plastic mesh-like member (31) and a filtration material (32), which captures oil mist contained in gas passing through the filter element (13). The filter element (13) is formed in a tubular shape by spirally winding the mesh-like member (31) and the filtration material (32) together.