Thermally Welded Filter Element for High-Temperature Sealing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing filter elements face issues with robustness and cost-effectiveness, particularly in high-temperature environments, and traditional seal arrangements can block fluid flow or have an unattractive appearance.

Innovation Solution

A filter element with a support arrangement comprising a shell member thermally welded to the circumferential face of the filter medium pack, eliminating the need for adhesives and ensuring a leak-tight joint without additional seal members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PU seal arrangements are used, then sealing function is provided, but thermal stability deteriorates at high temperatures above 80°C

Engineering Contradiction:

Improvesealing functionVSAvoidthermal stability

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent removes the PU seal member from the filter element design, extracting the problematic sealing component that failed at high temperatures. The sealing function is then achieved through the thermal welding of the shell member to the filter medium pack, eliminating the need for temperature-sensitive adhesive materials.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical/adhesive-based PU seal arrangement with a thermal welding process. The shell member is thermally welded directly to the circumferential face of the filter medium pack, creating a permanent bond that maintains integrity at high temperatures where PU seals would fail.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If end-cap seal arrangements are used, then sealing function is provided, but fluid flow is blocked

Engineering Contradiction:

Improvesealing functionVSAvoidfluid flow

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent transitions from end-cap sealing (blocking fluid flow paths at the ends) to circumferential sealing (sealing around the perimeter). The shell member circumscribes the circumferential face of the filter medium pack, providing sealing in a different dimensional orientation that does not obstruct the straight-through fluid flow between inlet and outlet faces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If adhesives are used to attach support arrangement, then attachment is achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the attachment function with the sealing function into a single thermal welding process. The shell member is thermally welded to the filter medium pack, simultaneously achieving both secure attachment and leak-tight sealing in one operation, eliminating the need for separate adhesive application and curing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses heat as an intermediary to achieve attachment. Thermal welding employs heat as a mediator to fuse the shell member and filter medium pack materials together, creating a strong bond without requiring chemical adhesives or additional fastening components.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If PU seal arrangements are used, then sealing function is provided, but aesthetic appearance deteriorates

Engineering Contradiction:

Improvesealing functionVSAvoidaesthetic appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The patent removes the foamed PU seal member that caused aesthetic issues. The extruded appearance and irregular surface texture of foamed PU are eliminated by using thermal welding to attach the shell member, resulting in a cleaner, more uniform外观 that meets aesthetic requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

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 robust and cost-effective filter element with improved thermal stability and unobstructed fluid flow, achieved through thermal welding of a shell member to the filter medium pack.

Implementation Method 1

at least a portion of the shell member is thermally welded to the circumferential face of the filter medium pack

Methodology Applied

Scientific EffectThermal welding: Welding

Data Source

PatentUS20250332532A1Filter element and method of manufacturing a filter element

Publication Date: 2025.10.30 DONALDSON CO INC

AI summary

The present disclosure relates to a filter element comprising a filter medium pack and a support arrangement comprising at least a shell member, and wherein a portion of the shell member is thermally welded to a circumferential face of the filter medium pack. The present disclosure further relates to a method of manufacturing such a filter element, the method comprising heating at least a portion of the shell member of the support arrangement, positioning the shell member around the circumferential face of the filter medium pack, pushing the heated circumferential portion of the shell member against the circumferential face of the filter medium pack, and allowing the circumferential portion of the shell member to cool down.