Ultrasonic Embossing for Zigzag Filter Medium Layer Welding
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Solution Overview
Problem
Existing methods for producing zigzag-folded filter elements from multi-layer web-shaped filter media face difficulties in stabilizing and connecting layers during the folding process, leading to reduced mechanical stability and increased complexity.
Innovation Solution
An ultrasonic embossing unit is used to simultaneously emboss fold lines and weld layers together, creating a robust and stable connection that enhances the filter medium's stability and simplifies the folding process, allowing layers to shift relative to each other during embossing and folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If layers of multi-layer filter medium are connected before embossing, then layer stability is improved, but folding difficulty increases due to inability to shift during embossing and folding
Solution Approach 1:
The patent applies preliminary action by embossing fold lines into the multi-layer filter medium before the layers are connected. This creates predetermined folding paths that allow the layers to shift relative to each other during the embossing and folding processes, eliminating the manufacturing difficulty while maintaining layer stability in the final product
2Ease of manufacture
If layers are not connected before embossing, then folding ease is improved, but layer detachment occurs in the finished filter element
Solution Approach 1:
The patent embosses fold lines into the multi-layer filter medium before the layers are connected, creating predetermined folding paths. This preliminary action allows layers to shift during processing for ease of folding, while subsequent connection ensures layers remain attached in the finished product, resolving both requirements
3Device complexity
If welding is performed during embossing, then process complexity is reduced, but bond strength requirements increase
Solution Approach 1:
The patent combines the embossing and welding operations into a single integrated process step. The embossing unit simultaneously creates fold lines and welds the layers together at these lines, reducing overall process complexity while ensuring the bond strength at welding lines meets or exceeds the material strength of individual layers
Solution Approach 2:
The patent employs ultrasonic energy with specific frequency and amplitude parameters to achieve both embossing and welding simultaneously. By carefully controlling these energy parameters, the process achieves adequate bond strength while maintaining operational simplicity
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 results in a more stable and robust filter element with improved mechanical stability and simplified folding, achieving bond strength equal to or greater than the material strength within individual layers, and allows for precise zigzag folding with reduced mechanical stresses.
Implementation Method 1
an energy-transferring embossing unit, in particular an ultrasonic embossing unit, with which fold lines are embossed in the web-shaped filter medium and the layers are welded together
Implementation Method 2
it simultaneously embosses the filter medium along the fold lines and welds the layers together there
Data Source
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AI summary
The invention relates to a device (10) and method for producing a filter medium (13) that is folded in a zigzag shape, in particular a filter medium of a motor vehicle, and made of a web-shaped filter medium (12). Via a feed system (18, 22), the web-shaped filter medium (12) is fed to an ultrasonic embossing unit (24) which embosses bending lines into the web-shaped filter medium (12). Subsequently, the filter medium (12) is folded along the bending lines by means of a folding system (42). During embossing, layers (14, 16) of the multi-layer filter medium (12) are welded together along the bending lines.