Air Filter Medium With Segmented Packing Densities
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Solution Overview
Problem
Air filters for internal combustion engines face limitations in dirt particle storage capacity and performance due to increased pressure loss, leading to decreased engine performance over time.
Innovation Solution
The air filter element features a dual-layer filter medium with distinct packing densities and a nanofiber layer, where the first filter layer section has a high porosity for larger particles and the second filter layer section with lower porosity filters finer particles, ensuring efficient dirt particle separation and extended filter life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single filter layer with uniform packing density is used, then the filter structure is simple, but the dirt particle storage capacity is limited and pressure loss increases over time
Solution Approach 1:
The filter medium is divided into multiple filter layers with different packing densities. The first filter layer has a first packing density and the second filter layer has a second packing density that differs from the first, allowing different sections to handle different particle sizes and storage requirements, thereby increasing overall dirt particle storage capacity while maintaining manageable structural complexity
Solution Approach 2:
Different sections of the filter medium are assigned different local properties through varying packing densities. The first filter layer section has higher porosity for larger particles while the second filter layer section has lower porosity for finer particles, optimizing each local region for its specific filtration function and increasing overall storage capacity
2Quantity of substance
If a filter layer with high porosity is used, then larger dirt particles can be filtered, but finer dirt particles cannot be effectively separated
Solution Approach 1:
The filtration function is segmented across multiple layers: the first filter layer with higher porosity handles larger particles, while the second filter layer with lower porosity handles finer particles. This segmentation allows each layer to be optimized for its specific particle size range, achieving both broad particle size range filtration and fine particle separation precision
Solution Approach 2:
Each filter layer is assigned a specific local quality in terms of porosity and packing density. The first filter layer has higher porosity optimized for larger particles, while the second filter layer has lower porosity optimized for finer particles, allowing simultaneous achievement of broad particle size range filtration and fine particle separation precision
3Duration of action of stationary object
If the filter medium stores more dirt particles, then the filter life is extended, but the pressure loss increases and engine performance decreases
Solution Approach 1:
The filter medium is segmented into multiple layers with different packing densities that work together to extend filter life. The distributed storage capacity across layers with varying porosity allows the filter to accommodate more dirt particles before reaching pressure loss thresholds that would impact engine performance, thereby extending operational duration
Solution Approach 2:
The packing density parameter is varied across different filter layers to optimize both dirt particle storage capacity and pressure loss characteristics. By changing the packing density from the first filter layer to the second filter layer, the system achieves extended filter life while maintaining acceptable pressure loss levels for sustained engine performance
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 configuration enhances dirt particle storage capacity and maintains engine performance by effectively filtering a broader range of particle sizes, reducing pressure loss and extending the filter's operational life.
Implementation Method 1
the comparatively large dirt particles first, i. H. through the first filter layer section with a high porosity value, and the finer dirt particles through the second filter layer section with a lower porosity value
Implementation Method 2
the comparatively large dirt particles first, i. H. through the first filter layer section with a high porosity value, and the finer dirt particles through the second filter layer section with a lower porosity value
Implementation Method 3
The second filter layer additionally provides a final filter function through a nanofiber filter layer. This allows the smallest dirt particles to be filtered out of the fluid flow to be filtered
Data Source
Figure 1~2
Figure 3~4B
Figure 5~6C
AI summary
A filter medium, particularly an air filter medium (100) comprises a first filter layer (110) and a second filter layer (120). The first filter layer comprises a first filter layer section (111) and a second filter layer section (113), which is arranged after the first filter layer section in a through-flow direction (103) of the filter medium (100). The first filter layer section (111) has a first fibre packing density and the second filter layer section (113) has a second fibre packing density which differs from the first fibre packing density. The second filter layer (120) is arranged after the first filter layer (110) in the through-flow direction (103) and has nano-fibres.