Thermoplastic Fuel Pre-Filtering Element With Integrated Sealing
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Solution Overview
Problem
Current fuel pre-filtering elements for diesel and biodiesel engines are costly due to metallic materials and require seals and welding, which complicates manufacturing and disposal, and lack a novel structural form to address water presence issues effectively.
Innovation Solution
A fuel pre-filtering element using synthetic fabric annular elements and thermoplastic welding to eliminate the need for internal seals, with a design that includes a casing, internal tube, upper and lower annular elements, and a filtering element, where the upper annular element forms a seal with the fuel outlet and the cover is fixed using thermoplastic welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for fuel pre-filtering element construction, then structural strength and durability are improved, but manufacturing cost and disposal complexity increase
Solution Approach 1:
The patent replaces expensive metallic materials with inexpensive thermoplastic materials that can be easily manufactured and disposed of. The filter element is designed as a disposable component made from cost-effective plastics, eliminating the need for costly metal construction while maintaining functional performance.
Solution Approach 2:
The patent changes the material parameter from metal to thermoplastic polymer, fundamentally altering the construction approach. This material substitution enables simpler manufacturing processes, reduced costs, and easier disposal while maintaining the structural integrity needed for filter functionality.
2Reliability
If metallic materials and seals are used in fuel pre-filtering elements, then connection reliability is improved, but device complexity and disposal difficulty increase
Solution Approach 1:
The patent merges the sealing function directly into the filter element body by integrating an annular sealing projection made from the same thermoplastic material. This eliminates the need for separate seal components and complex assembly procedures, reducing device complexity while maintaining reliable sealing connections.
Solution Approach 2:
The patent uses composite construction combining the filter media with an integrated sealing structure, both made from thermoplastic materials. This unified approach eliminates the need for multiple material types and separate sealing components, simplifying the overall device while ensuring reliable connections.
3Reliability
If traditional filtering elements with seals are used, then sealing effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The sealing function is merged into the filter element body through an integrated annular sealing projection. This single-piece construction eliminates separate seal components and complex assembly steps, significantly reducing manufacturing complexity while maintaining effective sealing performance.
Solution Approach 2:
The patent changes the sealing approach from using separate elastomeric seal components to using an integrated thermoplastic sealing projection. This material and structural parameter change simplifies manufacturing by enabling one-step molding while maintaining reliable sealing effectiveness.
4Strength
If metallic fuel pre-filtering elements are used, then structural integrity is improved, but environmental disposal difficulty and cost increase
Solution Approach 1:
The patent designs the filter element as a disposable component made from thermoplastic materials that are easier to dispose of than metals. The simplified material construction enables straightforward recycling or disposal processes, reducing environmental impact and disposal costs compared to metallic alternatives.
Solution Approach 2:
The patent changes the material parameter from metal to thermoplastic polymer, which fundamentally improves disposal characteristics. Thermoplastic materials can be more easily recycled or disposed of through standard plastic waste streams, reducing the environmental burden associated with metal disposal while maintaining sufficient structural integrity for filter application.
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 solution reduces manufacturing costs, simplifies the production and disposal of non-metallic components, and provides an efficient fluidic and mechanical connection, effectively removing water and impurities from fuel without the need for seals, thereby enhancing engine performance and longevity.
Implementation Method 1
the upper annular element is deformed and forms an annular projection, the annular projection establishing a seal between the internal tube, the fuel outlet and the casing
Implementation Method 2
uses thermoplastic welding to fuse the cover to the lower surface 10b of the casing
Implementation Method 3
a single coalescing filtering means that on its surface collects the drops of water present in the fuel until larger drops form and settle out
Implementation Method 4
collects the drops of water present in the fuel until larger drops form and settle out
Data Source
AI summary
A fuel pre-filtering element may comprise a casing provided with a fuel outlet, an internal tube, an upper annular element, a lower annular element, a filtering element and a cover. The filtering element may be arranged around the internal tube The upper and lower annular elements may be respectively fixed to the upper and lower ends of the filtering element The filtering element may be arranged inside the casing such that the internal tube establishes a contact with the fuel outlet, the upper annular element is arranged around the fuel outlet and in contact with an upper surface of the casing, and the upper annular element is deformed and forms an annular projection. The annular projection may establish a seal between the internal tube, the fuel outlet and the casing. The arrangement of the filtering element may be inside the casing and further form a region of unfiltered fuel.