Border Integrity and Multi-Layer Matrix Synergy
In high-pressure filtration systems-particularly plastic extrusion screen changers and high-viscosity liquid loops-standard unframed wire mesh discs present severe operational hazards. As process pressure builds, unframed disc edges tend to fray, shedding individual wire fragments directly into the downstream process flow. Furthermore, under high differential pressure, loose mesh layers warp and separate, leading to uneven fluid distribution, rapid pore blinding, and severe edge bypass around the filter housing seal.
Our Multi-Layer Stainless Steel Mesh Filter Leaf Discs solve these structural weaknesses through integrated rim encapsulation.
The inner multi-layer mesh matrix is arranged in a graded density sequence: fine active filtration mesh in the center, flanked by coarser protective and drainage wire cloth layers. The entire perimeter is then encapsulated within a precision-stamped metal rim (Aluminum, Copper, or SS 316L) and mechanically crimped under heavy hydraulic pressure. This continuous metallic border completely seals all loose wire ends, prevents edge fraying, enforces perfect circularity tolerances (≦0.1mm), and provides a robust sealing face that seats flush against equipment housing walls.
Details
Technical Specifications
Our framed filter leaf discs are manufactured to strict industrial tolerances:
| Structural Parameter | Generic Unframed / Hand-Cut Discs | Our Precision Framed Filter Leaf Discs |
| Outer Diameter Tolerance | ±0.5mm to ± 1.0mm | ≦±0.1mm Stamped / Laser Precision |
| Edge Fraying Protection | Unsealed loose wire ends (High Risk) | 100% Encapsulated Crimped Metal Rim |
| Layer Bonding Method | Loose stacking / Intermittent spot welds | Continuous Mechanically Crimped Perimeter Rim |
| Pressure Surge Resistance | Prone to mesh separation under △P | Rigid Multi-Layer Sandwich Structural Stability |
| Filtrate Edge-Bypass Risk | High (Irregular disc perimeter) | Zero-Bypass (Flush Gasket-Face Sealing) |
| Surface Flatness Tolerance | High risk of warping or cupping | ≦0.2mm Planar Stamping Flatness |
Key Performance Advantages Rooted in Our Manufacturing Process
● Absolute Edge-Fraying Elimination: Encapsulating wire cloth ends inside a continuous metallic rim prevents loose wire strands from breaking off into downstream pumps, extrusion dies, or high-purity fluid streams.
● Enhanced Sealing Integrity: The flat, crimped metal rim acts as a built-in compression gasket. When clamped inside filter housings or screen changers, it forms a tight mechanical barrier that eliminates perimeter slurry bypass.
● Graded Pore Density Optimization: Multi-layer packs utilize coarse outer layers to catch large contaminants, protecting the inner fine-micron mesh from premature blinding and extending disc working lifespan by up to 50%.
Send us your required disc diameter, layer mesh sequence, micron rating, and rim material choice. Our production line can handle high-volume OEM orders with precise stamping tooling and fast lead times.
Our address
Room 1310-5, Block A, Zhongliang Plaza, No. 345 Youyi North Street, Lianmeng Road, Xinhua District, Shijiazhuang City, Hebei Province, China 050061
Phone Number
+8615076820259
jesse@chgmetal.com
Frequently Asked Questions (FAQ)
Q: 1. What is the main advantage of an aluminum framed disc compared to a spot-welded multi-layer disc?
A: Spot-welded discs hold layers together at isolated points, but the perimeter wires remain exposed and can fray under flow shear. An aluminum framed filter leaf disc completely encapsulates the rim in a soft metal channel, which locks all layers together, eliminates wire shedding, and acts as a compression gasket inside the filter slot.
Q: 2. How do I select the right layer combination for high-viscosity polymer extrusion?
A: For high-viscosity polymers, we recommend a 3-layer or 5-layer symmetrical pack. The central layer is the fine filtration mesh (e.g., 200 mesh), supported on both sides by medium support layers (e.g., 80 mesh) and outer heavy protective grids (e.g., 20 mesh). This prevents the fine mesh from distorting under high extrusion pressure.
Q: 3. What dimensional details are required to order custom-sized filter leaf discs?
A: Riverbanks, reservoirs, and coastal erosion control Slope stabilization and landslide protection Highway and railway embankment reinforcement Bridge abutment and culvert protection Garden retaining walls and landscape decoration Military and noise barrier walls (e.g., Hesco barriers)
Q: 4. Gabion Mesh Production Process
We require the exact outer diameter (OD), inner diameter (ID) if a center hole is present, total disc thickness/layer count, micron rating or mesh count for each layer, border material preference (Aluminum, SS304, SS316L, Copper), and operating fluid temperature.
