Water Separator Screen Fabric Embedding via Laser Plastification
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Solution Overview
Problem
Conventional water separators in fuel filters have a reduced active separation surface area due to the presence of transverse and longitudinal ribs, which compromises their water separation capacity.
Innovation Solution
A method involving a support structure with a hydrophobic screen fabric arranged on its outer circumference, where the screen fabric is embedded in plastified regions of the support structure using ultrasound or laser radiation, maintaining a larger active surface area for water separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If transverse and longitudinal ribs are added to stabilize the screen, then mechanical stability is improved, but the active separation surface area is reduced
Solution Approach 1:
The patent removes the conventional ribs from the support structure and replaces them with a mesh-like framework. This extraction of the rib structure eliminates the obstruction to the screen fabric's active surface area while maintaining structural stability through the mesh design, allowing the screen to be embedded without reducing its effective separation area.
Solution Approach 2:
The patent employs a composite support structure combining a mesh framework with an embedding material (such as plastic or metal) that penetrates through the mesh. This composite approach provides mechanical stability through the combined strength of the mesh and embedding material, while the screen fabric can be fully embedded without ribs blocking its active surface area.
2Strength
If the screen is embedded in plastic material, then mechanical stability is improved, but the active separation surface area is reduced due to ribs
Solution Approach 1:
The patent extracts the rib structure from the embedding process, allowing the screen fabric to be embedded directly into a mesh framework without the obstruction of ribs. This enables the embedding material to penetrate through the mesh and secure the screen fabric while maintaining the full active surface area of the screen for water separation.
Solution Approach 2:
The patent uses a mesh framework that acts as a flexible support structure, allowing the screen fabric to be embedded through it. The mesh framework provides structural integrity while enabling the screen fabric to maintain its full surface area for separation, as the mesh openings allow embedding material to pass through without creating rib obstructions.
3Ease of manufacture
If conventional injection molding is used, then manufacturing simplicity is maintained, but only one transverse rib can be formed
Solution Approach 1:
The patent replaces the conventional injection molding process with a process involving a mesh framework and embedding material that penetrates through the mesh. This substitution allows for multiple transverse ribs to be formed by adjusting the mesh framework configuration, while maintaining manufacturing simplicity through the use of standard embedding techniques and the ability to form ribs after the screen is positioned.
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 approach maximizes the hydrophobic active surface area of the screen fabric, enhancing water separation efficiency while maintaining mechanical stability without reducing the effective separation surface area.
Implementation Method 1
plastifying the material of the support structure in regions that are radially outward in relation to the longitudinal axis by ultrasound or by laser radiation
Implementation Method 2
plastifying the material of the support structure in regions that are radially outward in relation to the longitudinal axis by ultrasound or by laser radiation
Implementation Method 3
pressing the screen fabric into the plastified regions
Data Source
AI summary
In a method for producing a water separator, a support structure surrounding annularly a longitudinal axis and a hydrophobic screen fabric are provided. By ultrasound or by laser radiation, a material of the support structure is plastified in regions that are radially outward at the support structure in relation to the longitudinal axis to generate plastified regions. The hydrophobic screen fabric is arranged at an outer circumferential side at the support structure and the hydrophobic screen fabric is pressed into the plastified regions. A water separator is provided that has a support structure surrounding annularly a longitudinal axis and a hydrophobic screen fabric of a material that is transparent for a laser radiation. The hydrophobic screen fabric is arranged at an outer circumferential side at the support structure and has sections embedded in radially outwardly positioned regions of the support structure.