Z-Filter Media Pack Sealing with Molded Polyurethane End Pieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter media technologies face challenges in effectively sealing individual flute ends in z-filter constructions, leading to issues with contaminant removal efficiency due to large sealant surface areas and volumes at flow ends.
Innovation Solution
The use of a stacked z-filter media pack with molded polyurethane end pieces and a molded-in-place seal arrangement, along with a corrugated media sheet and facing sheet configuration, to secure and seal the media pack, enhancing the sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sealant methods are used to seal flute ends in z-filter constructions, then the sealing process can be performed with simple equipment, but the sealant surface area and volume become excessively large, reducing contaminant removal efficiency
Solution Approach 1:
The invention changes the physical state and application method of the sealant from traditional liquid/coated applications to molded solid end pieces. The sealant is transformed into a pre-formed molded component that precisely fits the flute ends, reducing the volume of sealing material needed while improving sealing precision and contaminant removal efficiency.
Solution Approach 2:
The invention divides the sealing function into separate molded end pieces that are applied to individual flute ends. This segmentation allows for precise placement of sealant only where needed at the flute terminations, rather than requiring large surface areas of sealant across the entire filter media, thus reducing total sealant volume while improving sealing effectiveness.
2Reliability
If molded polyurethane end pieces are used to seal flute ends, then sealing efficiency and contaminant removal are improved, but the device complexity increases due to additional molding and assembly steps
Solution Approach 1:
The invention combines multiple functions into the molded end pieces: sealing of flute ends, structural support for media edges, and flow distribution. By integrating these functions into a single molded component, the design reduces the number of separate parts and assembly steps compared to using separate sealants, fasteners, and support structures, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The invention uses composite construction with media packs made from multiple layers (inlet flutes, outlet flutes, and sealing layers) combined with molded polyurethane end pieces. This composite approach creates a more reliable sealing system that efficiently removes contaminants while the modular composite structure facilitates easier assembly and maintenance.
3Stability of the object's composition
If the corrugated media sheet is secured to the facing sheet with extensive sealant, then the media pack structure is stabilized, but the manufacturing precision and sealing efficiency decrease due to large sealant volumes
Solution Approach 1:
The invention applies preliminary action by pre-molding the sealant into precisely shaped end pieces before assembly. These pre-formed molded end pieces are designed with exact dimensions and sealing surfaces that fit the flute ends perfectly, ensuring high manufacturing precision and stable media pack construction without requiring large volumes of sealant or complex application processes.
Data Source
AI summary
An air filter arrangement is (300) disclosed. The air filter arrangement includes strips of media comprising corrugated sheets secured to facing sheets and forming inlet and outlet flutes secured to one another in a stack. Media pack arrangements including such stacked media with a molding arrangement to secure and seal opposite side edges of the media strips, are described. Also described are filter cartridges including such media pack (301) and air cleaners including the filter cartridges. Methods of assembly and use are also provided. Also, systems of use are described.