Unitary Blow-Molded Pool Filter Tank With Integral Underdrain
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Solution Overview
Problem
Conventional sand filter units for swimming pools require separate construction of the housing and base, leading to suboptimal manufacturing processes and increased costs due to the need for different materials and structures to support the weight of sand and water.
Innovation Solution
A unitary filter tank with an integrally formed housing and base, where the base is reinforced using multiple layers of polymer that are folded and pinched together during manufacturing, providing a durable platform for the filtrate material and water, and an underdrain assembly with interlocking components that reduce assembly complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate construction of housing and base is used, then manufacturing flexibility is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the housing and base into a single unitary filter tank structure. The base is formed as an integral part of the housing through a single blow-molding process, eliminating the need for separate construction and assembly of these components. This merging reduces assembly complexity while maintaining manufacturing efficiency through the unified molding process.
2Adaptability or versatility
If separate construction of housing and base is used, then structural adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by reinforcing specific areas of the base with additional polymer material during the blow-molding process. The base includes a first portion with standard wall thickness and a second portion with increased wall thickness to provide enhanced structural support where needed. This localized reinforcement achieves structural adaptability while avoiding the need for completely separate base construction, thereby reducing manufacturing cost.
3Ease of operation
If conventional underdrain assembly with separate parts is used, then assembly flexibility is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent integrates the underdrain assembly directly into the unitary filter tank structure during the same blow-molding process. The underdrain is formed as an integral component within the base, eliminating the need for separate assembly of multiple underdrain parts. This merging simplifies the overall assembly process while maintaining the functional flexibility of the underdrain system.
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 unitary filter tank design offers a cost-effective and durable solution for filtering pool water, with the underdrain assembly providing efficient manufacturing and installation while maintaining performance comparable to conventional systems.
Implementation Method 1
The blow pin can be introduced into the mold and into an interior area of the molten polymer body and can blow or force air into the molten polymer body to expand the molten polymer body outward towards contoured surfaces of the mold
Implementation Method 2
The blow pin can continue to blow air to cool and harden the molten polymer body
Data Source
AI summary
Exemplary embodiments include a unitary pool filter tank and/or an underdrain for a pool filter unit. Embodiments of the unitary pool filter tank can have an integrally formed housing and base. The filter tank can be formed using a blow molding process in which the base of the filter tank is includes a support section and a punted section that has an underdrain mounting member. Embodiments of the underdrain can be formed by interlocking top and bottom components. The top and bottom components can be interlocked by inter-component locking structures.