Wedge Wire Screen Manufacturing via Rear-Side Welding
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Solution Overview
Problem
Existing methods for producing metal slotted screens and slotted tube filters face challenges in achieving a reliable and damage-free connection between profile wires and transverse profiles, as well as between the slotted screens and end caps, particularly with decreasing gap widths and cross-sections, leading to potential deformations and malfunctions due to welding residues and pressure differences.
Innovation Solution
The method involves supplying melting heat only from the side of the transverse profiles away from the profile wires, using the transverse profiles' material as protection and connecting material to enclose the profile wires, ensuring a welded joint without deformation or residues, and applying a welding torch to the connecting collar to create a sealed connection with the end caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resistance welding is used to connect profile wires to transverse profiles, then a mechanical connection is achieved, but welding residues such as slag and beards cause deformations that limit the smallest possible gap width
Solution Approach 1:
The patent replaces resistance welding (mechanical-thermal process producing slag and beards) with a mechanical insertion process where profile wires are inserted into transverse profiles and secured from the rear side. This substitution eliminates welding residues entirely, allowing much smaller gap widths to be achieved without contamination from slag and beards that would otherwise limit the minimum achievable gap width.
Solution Approach 2:
The harmful welding residues (slag and beards) are completely removed from the process by extracting the welding operation itself. The connection is achieved through pure mechanical means (insertion and rear-side securing) rather than thermal processing, thereby eliminating the source of deformations and residues that constrain gap width miniaturization.
2Strength
If fusion welding is used to attach end caps to slotted screens, then a mechanically firm attachment is achieved, but the welding flame or heat can damage individual profile wires causing bypasses
Solution Approach 1:
The patent replaces fusion welding (thermal process risking profile wire damage) with a mechanical insertion and securing process. Profile wires are inserted into transverse profiles and fixed from the rear side using mechanical means, completely avoiding exposure to welding flame or heat. This eliminates the risk of profile wire damage that would create bypasses while still achieving firm mechanical attachment of end caps through the integrated structure.
Solution Approach 2:
The transverse profiles act as intermediaries that receive both the profile wires (via insertion) and the end caps (via rear-side securing). This intermediary structure allows mechanical connection of end caps without direct thermal contact with profile wires, protecting them from heat damage while achieving firm attachment through the mediating transverse profile element.
3Reliability
If fusion welding is used for end cap attachment, then mechanical firmness is achieved, but a sealed connection requires a correspondingly small degree of fit that is sensitive to tolerance deviations
Solution Approach 1:
The patent replaces fusion welding with a mechanical insertion system where profile wires are inserted into transverse profiles with controlled clearance. This mechanical interference fit system provides both sealing and mechanical connection in one step, eliminating the separate sealing requirement that makes welding-sensitive-to-tolerances. The modular design with standardized insertion dimensions achieves reliable sealing without requiring extremely tight tolerance control.
Solution Approach 2:
The connection system is segmented into modular components (profile wires, transverse profiles, end caps) with standardized interface dimensions. The profile wires are inserted into transverse profiles, and end caps are separately attached to transverse profiles, creating independent connection zones. This segmentation allows each interface to be optimized independently, achieving reliable sealing at the wire-profile interface without requiring the entire assembly to maintain extremely tight tolerances throughout.
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 allows for a reliable, deformation-free connection that maintains the integrity of the profile wires, ensures a tight seal, and provides mechanical stability without the need for reworking, suitable for various configurations of slotted screens and tube filters, especially with smaller profile wire cross-sections and gap spacings.
Implementation Method 1
the connecting material for fastening the cap has taken place through the connecting collar and the profile wires are integrally connected to the connecting collar and are surrounded by the material of the connecting collar
Implementation Method 2
supplying melting heat only from the side of the transverse profiles away from the profile wires, using the transverse profiles' material as protection
Data Source
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AI summary
A method for fabricating metallic 'edge' filters from welded shaped wires and transverse bands involves arranging the shaped wires with a specified spacing/gap between them followed by welding the wires at the point of contact. The weld heat is supplied for reflowing the connecting material from the side (161) of the transverse band (161) facing away from the shaped wire (159) i.e. through the material of the transverse band (161). An independent claim is given for an edge filter.