Air filter assemblies and carrier frames having vortex-generating flow guide
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Solution Overview
Problem
Imperfections in air filter element construction, such as pleat bunching and embossments, cause non-uniform airflow velocity profiles, leading to variability in mass airflow sensor readings due to part-to-part differences in filter elements.
Innovation Solution
A carrier frame with integrated vortex-generating flow guides, such as tilted trapezoidal tabs or helical vanes, is used to normalize airflow velocity profiles by redirecting air into vortex flow paths, minimizing variations at the mass airflow sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional air filter elements are used with standard construction, then manufacturing is simpler and cost is lower, but airflow velocity profiles become non-uniform due to pleat bunching and embossments, causing variability in mass airflow sensor readings
Solution Approach 1:
A carrier frame with integrated vortex-generating flow guides is introduced as an intermediary component between the filter element and the mass airflow sensor. The flow guides redirect airflow into vortex flow paths, promoting rapid mixing and normalizing the velocity profile before air reaches the sensor, thereby minimizing variability in readings without requiring changes to the filter element construction itself
Solution Approach 2:
The invention changes the flow parameters (velocity profile, flow direction) by introducing vortex-generating structures. The carrier frame includes flow guides that transform the non-uniform axial flow into vortex flow patterns, which then mix and normalize the velocity profile, effectively changing the flow characteristics to achieve uniform distribution at the sensor location
2Measurement precision
If vortex-generating flow guides are added to normalize airflow, then mass airflow sensor variability is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The vortex-generating flow guides are merged with the carrier frame structure, integrating multiple functions into a single component. The carrier frame simultaneously provides structural support for the filter element and incorporates flow normalization features, eliminating the need for separate components and simplifying the overall manufacturing process
Solution Approach 2:
The carrier frame is designed with multi-functionality, serving both as a structural support framework and as an active flow control device. The integrated flow guides perform both structural and aerodynamic functions, reducing the total number of parts and simplifying manufacturing while achieving the desired flow normalization effect
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 effectively reduces mass airflow sensor variability by promoting rapid mixing and establishing a uniform velocity profile downstream of the air filter element, compensating for manufacturing imperfections in filter elements.
Implementation Method 1
A carrier frame with integrated vortex-generating flow guides, such as tilted trapezoidal tabs or helical vanes, is used to normalize airflow velocity profiles by redirecting air into vortex flow paths
Data Source
AI summary
Air filter assemblies and carrier frames have a plurality of vortex-generating flow guides normalizing air flow to a uniform velocity profile downstream thereof. The airflow having the uniform velocity profile travels across a mass airflow sensor.