Zigzag Filter Insert Manufacturing with Glue Stabilization
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Solution Overview
Problem
Existing methods for producing zigzag folded filter inserts face challenges in maintaining precise positioning during transfer between production plants, leading to potential inaccuracies in filter element formation and assembly.
Innovation Solution
The method involves embossing folds in a filter medium, applying beads of glue to its side edges for stabilization, and using a metal strip as an intermediate carrier for the glue, which detaches and ensures consistent fold pitch and spacing, allowing for precise transfer and overmoulding with thermoplastic material to form a stable frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the filter medium is manually transferred between production plants, then the transfer process is simple, but the exact positioning of the filter medium is no longer guaranteed
Solution Approach 1:
The patent introduces reference marks as an intermediary element that facilitates precise positioning during manual transfer. These marks serve as a common language between different production plants, enabling operators to align the filter medium accurately without complex mechanical fixtures or automated systems.
Solution Approach 2:
The patent uses reference marks that can be copied or reproduced across different production plants. By having standardized reference marks on both the filter medium and the processing equipment, the same positioning information is replicated across different locations, ensuring consistency without requiring the original equipment to be present.
2Manufacturing precision
If beads of glue are applied to stabilize the zigzag folded filter medium, then the fold pitch and fold spacing are maintained precisely, but the process complexity increases
Solution Approach 1:
The patent applies beads of glue in advance during the folding process to stabilize the zigzag structure. This preliminary action ensures that the fold pitch and spacing are locked in early, preventing deformation during subsequent handling and transfer operations.
Solution Approach 2:
The patent uses disposable glue application elements that are simple and inexpensive. The beads of glue serve their stabilizing function and then are consumed or discarded, replacing complex reusable positioning mechanisms with a simple, single-use solution.
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 enables process-reliable production and assembly of filter elements with high precision, ensuring accurate fold maintenance and integration with end plates, even when transferring between devices, resulting in stable and accurately formed filter inserts.
Implementation Method 1
at least two beads of adhesive are applied to the surface of the filter medium
Implementation Method 2
overmoulding the filter element with a thermoplastic material to form a frame
Implementation Method 3
in a first step, creased edges are embossed
Data Source
Figure 1
Figure 2a~2c
Figure 3~4
AI summary
The method involves utilizing a zigzag shaped folded filtering agent, where the bending edges are stamped in a first step, and subsequently a folding is carried out, where two glue beads are applied on the side edges of the filtering agent after the folding, which run along the folded filtering agent. The folded filter material is separated into individual filter elements by a cutting device and the individual filter elements are inserted into a frame, which has a contour, which enables coating of the filter element with a thermoplastic synthetic material for building a frame.