Anti-Crown Support Grid for Vehicle Air Filter Deformation
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Solution Overview
Problem
Air filter elements in vehicle engines face deformation and increased pressure drops due to air flow-induced forces, especially in adverse climates, which can lead to mechanical failure.
Innovation Solution
An air filter assembly with an anti-crown support grid and alignment features, including side rails, frame attachment members, and support ribs, is integrated into the seal frame to provide mechanical support and resist deformation, while alignment features ensure proper housing alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media is used to capture particulate contaminants, then air cleaning effectiveness is improved, but air flow restriction and pressure drop increase
Solution Approach 1:
The filter element is divided into multiple pleated sections, increasing the total filter surface area while maintaining compact dimensions. This segmentation allows more filter media to be incorporated without proportionally increasing air flow resistance, as the pleated structure creates multiple parallel flow paths through the filter media.
2Strength
If support frame is added to reinforce filter media, then structural strength is improved, but device complexity increases
Solution Approach 1:
The support frame and seal frame are merged into a single integrated peripheral structure that provides both mechanical support and sealing functions. This combination eliminates the need for separate support and sealing components, reducing overall device complexity while maintaining structural strength.
Solution Approach 2:
The peripheral frame structure serves multiple functions simultaneously: it provides mechanical support to prevent filter media deformation, creates a seal between the filter element and housing, and offers attachment points for mounting. This multi-functionality reduces the number of separate components needed.
3Adaptability or versatility
If filter element operates in adverse climate conditions, then air intake function is maintained, but deflection forces and pressure drop increase
Solution Approach 1:
The integrated support frame is designed with sufficient structural rigidity to counteract deflection forces from snow, ice, and water accumulation before these forces can cause filter media deformation or failure. The frame's geometry and material selection provide preliminary resistance to adverse climate conditions.
Solution Approach 2:
The peripheral frame structure acts as a protective barrier that absorbs and distributes the impact of accumulated snow, ice, and water before these forces reach the filter media. This cushioning effect prevents direct transmission of high deflection forces to the delicate filter pores.
4Manufacturing precision
If alignment features are added to support grid, then housing alignment precision is improved, but device complexity increases
Solution Approach 1:
Alignment features are integrated directly into the support grid structure, combining the alignment function with the existing mechanical support framework. This integration eliminates the need for separate alignment components while ensuring precise housing alignment during installation.
Solution Approach 2:
The support grid structure serves dual purposes: providing mechanical support to the filter media and ensuring precise alignment with the housing through integrated alignment features. This multi-functionality maintains manufacturing precision without adding separate alignment devices.
Data Source
AI summary
An air filter element is provided with an anti-crown support grid on a clean side of the filter media. The support grid includes one or more elongated mounting members provided along periphery portions of the grid and at least one support rib spanning between and secured at opposing ends to the mounting members. The mounting members are embedded within a peripheral seal frame. The support grid may include at least one alignment feature sized, configured and positioned to be receivable into a complimentary feature of a housing so as to positionally lock the filter element and the housing.