Zigzag Filter Element with Discontinuous Bonding for Contour Sealing
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Solution Overview
Problem
Existing filter elements with zigzag-shaped filter media face challenges in mass production due to complex and costly adhesive application devices when the filter element has non-linear or slanted contours, leading to increased reject rates and difficulty in sealing fold ends, especially with recesses or indentations.
Innovation Solution
A filter element with a zigzag-shaped filter medium featuring discontinuous end edge bonding, comprising outward and inward bonding segments that are spaced apart, allowing for simpler adhesive application using conventional nozzles, reducing the need for high-dynamic devices and minimizing reject rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive application follows a non-linear contour with recesses, then sealing of fold ends is achieved, but device complexity and cost increase due to requirement of two-dimensional high-dynamically movable adhesive application devices
Solution Approach 1:
The adhesive application path is segmented into two distinct paths: a first adhesive application path that follows the outer contour including recesses, and a second adhesive application path that is linear and parallel to the fold direction. This segmentation allows the use of simple linearly movable devices for the second path while the first path can be handled by simpler means, resolving the contradiction between sealing reliability and device complexity.
Solution Approach 2:
The second linear adhesive application path acts as an intermediary that bridges the gap caused by recesses in the first adhesive application path. By applying adhesive along this parallel linear path, the system compensates for the complexity of following non-linear contours, enabling reliable sealing without requiring complex high-dynamic movable devices.
2Reliability
If adhesive application path extends at a slant relative to movement axis, then recess contours are followed, but productivity decreases due to inability to achieve great relative speeds in mass production
Solution Approach 1:
The adhesive application is segmented into two paths with different characteristics. The second adhesive application path is specifically designed to be linear and parallel to the fold direction, allowing it to be applied at high speeds during mass production. This linear path ensures adequate adhesive coverage without requiring complex slanted movement, thus maintaining productivity while still achieving reliable sealing when combined with the first path.
3Reliability
If adhesive bead application follows recess contours, then complete sealing is achieved, but manufacturing cost increases due to complex prone-to-wear adhesive application devices
Solution Approach 1:
The sealing function is segmented between two adhesive application paths. The second linear path can be implemented with simple, robust, and inexpensive adhesive application devices that are not prone to wear or disturbances. This linear path handles the majority of the sealing requirement, while the first path complements it, thereby achieving complete sealing without requiring expensive complex devices.
Solution Approach 2:
The second adhesive application path uses a simple linear configuration that can be implemented with inexpensive, easily replaceable adhesive application devices. These simple devices are less prone to wear and can be quickly replaced if needed, reducing manufacturing costs while maintaining sealing efficiency through the combined action of both adhesive paths.
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 solution enables cost-effective mass production of filter elements with improved sealing efficiency and maximized filter surface utilization, while maintaining a low reject rate and ensuring reliable sealing even with non-linear contours.
Implementation Method 1
The filter element is provided with an end edge bonding for sealing its fold ends... When an adhesive bead is employed for forming the end edge bonding... the end edge bonding comprises at least one outwardly arranged first bonding segment and comprises a second bonding segment inwardly positioned in fold direction
Data Source
AI summary
A filter element for filtering a fluid has a filter body with a filter medium folded in a zigzag shape with folds extending in a fold direction. The filter body has an end edge bonding which seals fold ends of the folds. The filter body has an outer contour with recesses. The end edge bonding, in a region of the recesses of the outer contour of the filter body, is embodied discontinuously. The end edge bonding has at least one outwardly positioned first bonding segment and an inwardly positioned second bonding segment, viewed in the fold direction. The inwardly positioned second bonding segment, in a transverse direction relative to the fold direction, is arranged at a spacing to the at least one outwardly positioned first bonding segment. The at least one outwardly positioned first bonding segment and the inwardly positioned second bonding segment bond at least one common fold.