Axial Flat-Filter Element With Integrated Frame Sealing
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Solution Overview
Problem
Existing fuel cell systems require particle and harmful gas filtration technologies that are either costly or lack service-friendliness, and existing filter elements often require complex sealing mechanisms that complicate installation and maintenance.
Innovation Solution
A flat-filter filter element with at least two filter medium bodies arranged axially, connected by an overmolded plastic frame and circumferential cast elements, allowing for stable and sealed filtration without lateral bands, utilizing conventional injection molding and casting processes for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple filter medium bodies are arranged axially to improve filtration performance, then adsorption capacity and dust capacity are improved, but device complexity increases due to multiple connections and sealing requirements
Solution Approach 1:
The patent combines multiple filter medium bodies (particle filter and adsorption filter) into a single integrated filter element with a common frame. The frame integrates support, connection, and sealing functions, merging multiple structural elements into one unified component that houses both filter media types axially arranged.
Solution Approach 2:
The frame serves multiple functions simultaneously: it provides structural support for the filter medium bodies, creates sealing surfaces against the housing, enables connection between different filter sections, and defines the overall geometry of the filter element. This multi-functionality reduces the need for separate components.
2Reliability
If conventional sealing mechanisms are used to seal multiple filter medium bodies, then sealing reliability is improved, but ease of manufacture deteriorates due to complex assembly processes
Solution Approach 1:
The sealing function is merged into the frame structure itself. The frame includes integrated sealing surfaces that directly contact the housing, eliminating the need for separate sealing components. The frame and sealing mechanism become a unified structural element.
Solution Approach 2:
The patent changes the sealing approach from using separate sealing components to using the frame's geometric parameters and surface properties. The sealing effectiveness is achieved through precise dimensional design of the frame's contact surfaces with the housing, rather than through separate sealing materials or mechanisms.
3Reliability
If lateral bands are used to secure filter medium bodies, then connection reliability is improved, but device complexity increases due to additional components
Solution Approach 1:
The connection function is merged into the frame structure. The frame provides integrated support and connection for both the particle filter and adsorption filter media through its geometric design, eliminating the need for separate lateral bands or additional fastening components.
Solution Approach 2:
The patent extracts the connection function from separate lateral band components and integrates it directly into the frame structure. The frame itself becomes the connecting element, removing unnecessary intermediate components while maintaining connection reliability.
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
Provides a cost-effective and service-friendly filtration solution with improved adsorption capacity, dust capacity, and reduced pressure drop, while ensuring secure connection and sealing of filter medium bodies within the filter housing.
Implementation Method 1
an overmolded plastic frame (50) that is directly molded to an outer circumference (26, 46) of one of the filter medium bodies (12, 32)
Implementation Method 2
the other one of the filter medium bodies (12, 32) is sealingly connected to the overmolded plastic frame (50) by means of a circumferential cast element (20, 40)
Implementation Method 3
Fuel cell systems often require a particle filter and an adsorption filter to filter both particles and harmful gases from the intake air
Implementation Method 4
at least two 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
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 flat-filter filter element (10) comprises an overmolded plastic frame (50) that is directly molded to an outer circumference (26, 46) of one of the filter medium bodies (32, 12), and the other one of the filter medium bodies (12, 32) is sealingly connected to the overmolded plastic frame (50) by means of a circumferential cast element (20). The invention further relates to a filter system (100) as well as to a use of a flat-filter filter element (10).