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New complex polymer mesh filter for the automotive industry

Polyflter project will focus on development of complex polymer mesh filter used in fuel injection systems in automotive industry. Main goal is to provide new solution of filters manufacturing and achieve significant reductions in weight, co2 emissions and lower production cost and time.

Main goal of the PolyFlter project is to build a process for producing a mesh filter used in fuel filtration systems in automotive industry. Filtration systems are nowadays complying with the most stringent cleanliness requirements. In order to meet those requirements overmolding technique is starting to emerge in this field. In this case filter mesh is being overmoulded by a plastic filter cage (this two-component product is called PolyFilter in our case). Aditionally to cleanliness benefits there are of course also financial benefits using overmoulding technique. Compared to conventional method of glueing the mesh on the filter cage one step is eliminated and thus resulting in lower production costs. We had defined folloving objectives: 1. Objective – New product design: To design and manufacture a two-component product for automotive filtration systems. This products is to be used for fuel filtration. 2. Objective – New materials: Because the function of this product will change significantly due to the injection moulded filter cage materials with higher elastic modulus will be used. 3. Objective – High production technology – the new concept of more cavity tools: • Pouring material into channels. • Warm channels: T• Energy saving • Shorter work cycle • Robotisation and operation • Lower capital investment: 4. Objective – Integrated management of production processes: • Combining work operations • Integrated technological processes are combined in a single function consisting of one modular cell. 5. Objective – Developing competences: • Ongoing collaboration with the Faculty of Mechanical Engineering of the University of Ljubljana (FS), the leading national research institute in the field of robotics, handling, optimization of technological parameters and the integrated management of production processes. • The ability to form tools for two-component products. This will be enabled by the application development of new products in various sales segments, including appliances and electronics. One of the main focus of this project will be the way of handling with filter mesh during the overmoulding process. It is of utmost importance that the mesh is inserted on the exact position, without any damage and oriented correctly. One of the main anticipated challenges will be holding the mesh in this position during the whole overmoulding process without damaging it and thus changing the mesh geometry. Due to expected high volume production a 100% automated process will need to be guaranteed for the serial production tools. The prototype tool will be used to determine the most efficient way of handling with the filter mesh. We will try different methods of inserting the mesh in the mould tool and based on the findings choose the most efficient one. This method will be then transfered and adjusted to the serial production tools. A very important point of this project will be choosing a form in which the mesh will be delivered. There are various forms available on the market. Having a prototype tool on which we will test different forms of mesh will massively help us decide which ones to use. Choice of the form in which the mesh will be delivered will be influenced also by the price of the delivered goods. A combination of positive findings from prototype tool and the price of tested mesh forms will give us an answer to the question of which mesh form to use in serial production tools. During the project we will have to analyze which material will suit the best for the filter cage and have a good bonding properties with filter mesh. Apart from that the material will need to comply to certain demands as are for example flammability, temperature, geometrical and chemical resistance, mechanical properties, etc. To ensure a PolyFilter within a certain flow rate limits predefined by the customer, a fully automated system for 100% flow rate inspection will need to be developed. Together in combination with fully automated visual inspection Polycom will be able to provide a zero defects products. Being able to manage a process of overmoulding a filter mesh for the fuel filtration systems will give Polycom the ability to expend the technology also on other fields outside the automotive industry, as for example: air filtration systems (house hold appliances), blood transfusion kit (medicine segment), and many more.
Acronym: 
PolyFilter
Project ID: 
11 185
Start date: 
01-05-2017
Project Duration: 
36months
Project costs: 
850 000.00€
Technological Area: 
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.