Axial Flat-Filter Element With Overlapped Bands for Compact Dual Filtration
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Solution Overview
Problem
Existing fuel cell systems require particle and gas filtration technologies that are either costly or lack service-friendliness, and existing filter elements do not efficiently utilize installation space for adsorption and particle filtration.
Innovation Solution
A flat-filter filter element with at least two flat filter medium bodies arranged axially, connected via overlapping lateral bands embedded in a circumferential cast element, providing a stable and sealed connection for efficient filtration of particles and gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple filter medium bodies are arranged axially to enhance filtration efficiency, then filtration performance is improved, but the complexity of connecting and sealing these bodies increases
Solution Approach 1:
The patent combines multiple filter medium bodies (particle filter and adsorption filter) into a single integrated filter element with axial arrangement. The lateral bands of adjacent filter medium bodies overlap and are embedded in a common circumferential cast element, merging the connection and sealing functions into one integrated structure rather than using separate components for each function.
Solution Approach 2:
The circumferential cast element serves multiple functions simultaneously: it acts as a structural support, a sealing element, and a connection medium for the lateral bands of multiple filter medium bodies. This multi-functional design reduces the overall complexity by eliminating the need for separate sealing rings, support structures, and connection mechanisms.
2Stability of the object's composition
If lateral bands are embedded in a circumferential cast element for stable connection, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The cast element is manufactured as a single integrated component that simultaneously provides structural support, sealing, and lateral band embedding. This combines multiple functions into one manufacturing process, reducing the need for separate assembly steps for supports, seals, and connection elements.
Solution Approach 2:
The cast element is designed with specific geometric parameters that enable the lateral bands to be embedded directly during the casting process. The casting parameters (material, temperature, mold design) are optimized to create the embedding structure in a single step, avoiding complex post-manufacturing assembly operations.
3Reliability
If filter element size is increased to improve filtration capacity, then filtration capacity is improved, but space utilization efficiency decreases
Solution Approach 1:
The patent transitions from radial or lateral filter arrangements to an axial arrangement of filter medium bodies. This dimensional change allows multiple filter stages (particle filtration and adsorption) to be stacked along the axial direction, maximizing the use of available space in the filter housing while maintaining high filtration capacity.
Solution Approach 2:
The filter medium bodies are arranged concentrically and axially within the filter housing, with each filter stage nested within the overall cylindrical structure. The lateral bands and circumferential cast element create a compact nested arrangement that maximizes filtration capacity within the available volume.
Data Source
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AI summary
The invention relates to a flat-filter filter element (10) for filtering a fluid, in particular for filtering air, for a filter system (100), in particular for an air filter system of a fuel cell system, having an arrangement of at least two flat-filter medium bodies (12, 32) being arranged adjacent to each other in an axial direction (80) so that the fluid can flow through them one after the other in the axial direction (80). The filter medium bodies (32, 12) each comprise a lateral band (27, 48) at their outer circumference (26, 46). The lateral band (27, 48) of one of the filter medium bodies (12, 32) protrudes in axial direction (80) over the other one of the filter medium bodies (12, 32) and at least partly overlaps the lateral band (48, 27) of the other of the filter medium bodies (32, 12) in an overlapping region (72), the lateral bands (27, 48) in the overlapping region (72) being at least partially embedded in a circumferential cast element (40) arranged at a downstream side (21) of the arrangement of filter medium bodies (12, 32).