Wave-Seal Filter Element for Low-Cost Reliable Housing Sealing
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Solution Overview
Problem
Conventional fluid filter assemblies face challenges in achieving effective sealing with sufficient filtration capacity while maintaining ease of installation and replacement, and there are high manufacturing costs associated with co-injection molded covers and seals.
Innovation Solution
A filter element with an undulating sealing element made of urethane, directly bonded to the filter media, providing a wave seal configuration that enhances sealing efficacy and reduces manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an o-ring supported seal along a plane in a straight cut or radial seal gland design is used, then sealing is achieved, but manufacturing cost is high and installation is complex
Solution Approach 1:
The patent employs an undulating sealing element with a wave-like cross-sectional geometry instead of a conventional straight or radial seal gland design. This curved, undulating profile allows the seal to conform to the mating surface and achieve effective sealing through its natural elastic deformation, eliminating the need for complex radial seal glands or o-ring assemblies while reducing manufacturing cost and simplifying installation.
2Reliability
If a co-injection molded cover and seal elements are used, then sealing is achieved, but manufacturing cost is high
Solution Approach 1:
The patent separates the sealing function from the structural cover elements. Instead of co-injection molding the cover and seal as a single complex component, the invention uses a standalone undulating sealing element that is inserted into a simple recess in the cover. This segmentation allows each component to be manufactured independently using simpler, less expensive processes while maintaining effective sealing.
Solution Approach 2:
The undulating sealing element is designed as a simple, inexpensive component made from elastomeric material that can be easily replaced. Its simple geometry and material choice enable low-cost manufacturing compared to complex co-injection molded assemblies, aligning with the principle of using simpler, more economical components that can be readily replaced if needed.
3Reliability
If conventional seal designs are used, then sealing is achieved, but ease of installation and replacement is reduced
Solution Approach 1:
The undulating cross-sectional geometry of the sealing element provides natural compliance and adaptability during installation. The wave-like profile allows the seal to flex and conform to the mating surface as it is inserted, making installation straightforward without requiring precise alignment or complex assembly procedures. This same flexible geometry facilitates easy removal and replacement of the filter element.
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 filter element achieves comparable filtration efficiency with up to 99.9% performance and ease of installation, while reducing manufacturing costs through direct bonding and eliminating the need for additional components.
Implementation Method 1
An undulating sealing element is fixed to the outer face of the filter media... The sealing element is made of urethane
Data Source
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AI summary
A filter element is disclosed which is for use in a filter assembly including the filter element contained within a filter housing. The filter element comprises a filter media having a first face and a second face opposite to the first face, and an outer face extending in a longitudinal direction perpendicular to the first and second faces from the first face to the second face. The filter media has a curved cross section that is uniform from the first face to the second face. An undulating urethane sealing element is provided that is compressible within a mating groove of the filter housing, the urethane sealing element being directly bonded to the outer face of the filter media at a location closer to the first face than the second face, and offset from the first face.