Suction Filter Assembly With Clamped Coarse Stage and Bypass Valve
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Solution Overview
Problem
Existing suction filters for liquids, such as those used in automatic gearboxes, face design and assembly complexities due to overmoulding requirements and viscosity-related pressure drops, which increase costs and complicate operation, especially at colder temperatures.
Innovation Solution
A suction filter with a housing design featuring two open sides allows for clamping of a coarse filter element without overmoulding, using a polyester filter medium for leak-tight assembly and reduced costs, and incorporates a pleated fine filter element with multiple layers for enhanced filtration and pressure management, along with a bypass valve for pressure regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter elements are overmoulded in the housing to keep them in place, then the filter elements are secured, but the design and assembly become complicated and costs increase
Solution Approach 1:
The invention extracts the retention function from the housing structure and transfers it to the filter element itself through a groove and cover arrangement. The groove in the filter element receives a cover that is retained by the housing, effectively separating the retention mechanism from the housing design and simplifying assembly.
Solution Approach 2:
Instead of the housing retaining the filter element through overmoulding, the invention inverts the approach by having the filter element (via its groove and cover) retain itself within the housing. This reversal of the retention mechanism eliminates the need for complex overmoulding processes.
2Reliability
If traditional metallic wire mesh is used for coarse filter, then filtration is effective, but assembly leak-tightness is difficult to achieve and costs are higher
Solution Approach 1:
The invention changes the material parameter from traditional metallic wire mesh to polyester filter material. This material change enables leak-tight assembly edges that can be effectively sealed by the cover, while maintaining coarse filtration effectiveness and reducing manufacturing costs.
Solution Approach 2:
The invention uses polyester filter material as a composite solution that combines the filtration function with leak-tight assembly capability. The polyester material's properties allow it to be sealed effectively by the cover, creating both filtration and sealing functions in a single material.
3Ease of manufacture
If single-layer filter elements are used, then assembly is simple, but filtration efficiency is insufficient and clogging occurs early
Solution Approach 1:
The invention segments the filter element into multiple layers with different filtration functions. The coarse filter layer captures large particles, the fine filter layer captures smaller particles, and the support layer provides structural integrity. This segmentation maintains assembly simplicity while dramatically improving filtration efficiency and preventing early clogging.
Solution Approach 2:
The invention applies local quality by giving each layer of the filter element different properties tailored to its specific function. The coarse layer has larger pores for initial filtration, the fine layer has smaller pores for refined filtration, and the support layer has high strength for structural support, optimizing overall performance.
4Reliability
If filter units are designed for cold temperature operation, then viscosity-related pressure drops are reduced, but design complexity increases
Solution Approach 1:
The invention incorporates a bypass valve that dynamically adjusts based on pressure differential. When the filter becomes clogged or viscosity increases at cold temperatures, the bypass valve automatically opens to allow fluid to bypass the filter media, maintaining flow while protecting the filter element from excessive pressure drops.
Solution Approach 2:
The bypass valve is pre-configured to activate automatically when pressure differential exceeds a threshold, providing preliminary protection against cold temperature viscosity issues and early clogging before they become critical problems.
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 design simplifies the filter unit's assembly and reduces costs, maintains effective filtration efficiency, and manages pressure drops effectively across varying temperatures, ensuring reliable operation and reduced risk of clogging.
Implementation Method 1
a coarse filter element (21) arranged in the housing element (3) outside the first filter element (13)
Implementation Method 2
a first filter element (13), arranged inside the housing element (3), having a pleated structure extending in a radial direction
Implementation Method 3
the bypass valve including an orifice that is opened and closed in response to differential pressure across the valve
Data Source
AI summary
The present invention relates to a suction filter unit (1) for filtering liquids. The filter unit (1) comprises: a housing element (3) with an open first side and an open opposing, second side, the housing element (3) comprising a first set of filter element supporting elements (23); a first cover (5) sealingly connected to the first side of the housing element (3); a second, different cover (7) sealingly connected to the second side of the housing element (3), the second cover (7) comprising a second set of filter element supporting elements (25); a filter unit inlet (9); a filter unit outlet; a first filter element (13) for providing a fine filtering property of the liquid; and a second filter element (21) arranged between the first filter element (13) and the inlet (9) for providing a coarse filtering property of the liquid. The second filter element (21) is clamped between the second cover and the housing element (3) by the first and second set of filter element supporting elements (23, 25).