Welded Separator Plate Filter Integration
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Solution Overview
Problem
The manufacturing of conventional separator plates for hydraulic control units is complex, error-prone, and expensive due to the need for multiple individual parts and adhesive layers, which can be chemically aggressive and unsuitable for mass production, and often results in a thick plate that does not fit modern vehicle installations.
Innovation Solution
A separator plate design where the filter material is melted and welded onto a base plate in specific zones, eliminating the need for adhesive layers and allowing for a thin, stable, and even connection, with the melted zones positioned on the periphery to prevent disruption during sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive layers are used to connect filter material to base plate, then the filter material can rest evenly and flat on the base plate, but the manufacturing becomes expensive and the adhesives can be chemically aggressive and damage the filter material
Solution Approach 1:
The patent removes the adhesive layer from the separator plate structure entirely. Instead of using adhesive to connect the filter material to the base plate, the invention uses a self-adhering filter material that bonds directly to the base plate through its own adhesive properties, eliminating the need for separate adhesive layers and reducing manufacturing complexity
Solution Approach 2:
The filter material itself acts as an intermediary with inherent adhesive properties. The self-adhering filter material contains its own adhesive layer that bonds it to the base plate, serving both as the filter medium and the bonding agent, thereby eliminating the need for separate adhesive materials
2Reliability
If multiple individual parts and adhesive layers are used, then the filter material can be securely connected, but the separator plate thickness increases and does not fit modern vehicle installations
Solution Approach 1:
The patent merges multiple components into a single integrated structure. The base plate, filter material, and adhesive layer are combined into one thin separator plate assembly where the self-adhering filter material is directly bonded to the base plate, eliminating the need for separate adhesive layers and reducing overall thickness
Solution Approach 2:
The invention uses a thin-film structure where the self-adhering filter material acts as a flexible, thin bonding layer that securely connects the filter media to the base plate without adding significant thickness, enabling the separator plate to fit modern vehicle installation spaces
3Ease of manufacture
If adhesive layers are used, then the filter material can be connected to the base plate, but the adhesives can be processed only with high assembly costs and require particular care in mass production
Solution Approach 1:
The filter material is designed to be self-adhering, meaning it has built-in adhesive properties that allow it to bond to the base plate without requiring external adhesive application processes. This self-service capability eliminates complex adhesive processing steps and enables straightforward mass production
Solution Approach 2:
The patent extracts the adhesive function from separate processing steps and integrates it directly into the filter material itself. The self-adhering filter material contains its own bonding capability, eliminating the need for separate adhesive application, curing, and assembly processes that hinder mass production
4Strength
If the filter material is connected by adhesive layer, then the filter material can be securely attached, but the adhesive can be chemically aggressive and attack and damage the filter material
Solution Approach 1:
The patent uses a self-adhering filter material where the adhesive function is integrated into the filter material itself rather than using separate, potentially aggressive adhesive materials. The self-adhering property provides sufficient bonding strength without introducing external chemical aggressors that could damage the filter material
Solution Approach 2:
The invention changes the chemical parameters of the bonding system by using the filter material's own adhesive properties rather than external adhesives. This parameter change eliminates chemical incompatibility issues and ensures the bonding agent is chemically compatible with the filter material
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 reduces the thickness of the separator plate, increases stability, and eliminates the risk of adhesive-related issues, enabling a solid unit with reduced exposure to aggressive fluids and allowing for efficient fluid conduction through labyrinthine channel systems, suitable for modern vehicle installations.
Implementation Method 1
the filter material is melted onto or onto the base plate
Implementation Method 2
the filter material is melted or melted on in such a way that it forms a firm bond with the base plate. During the melting process, the filter material is glued or welded onto the base plate by the thermal impact
Implementation Method 3
This largely prevents the formation of waves in the filter material due to thermal stress. The melted zones are flattened compared to the non-melted areas of the filter material
Data Source
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AI summary
The plate has a sealing material, a baseplate (2) and a filter material (3) for filtering a fluid i.e. oil, where the baseplate is positioned between the sealing material and the filter material. Another sealing material (4) is attached to the baseplate at a filter side, where filter material is fused or partly fused on the baseplate. The sealing material (4) is integrated partly into the filter material, where the filter material is designed as wires (6) or a thread structure (5). The baseplate is made of a metal. An independent claim is also included for a method for manufacturing a separator plate.