Axial Flow Filter Element With Support Rings
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Solution Overview
Problem
The high cost and environmental impact of injection-molded plastic components in air filter elements, which contribute significantly to the overall cost and generate non-biodegradable waste upon disposal, necessitate a more sustainable and cost-effective solution for axial flow air filtration systems.
Innovation Solution
The axial flow filter element design incorporates upper and lower support rings that circumscribe the filter media, with the upper support ring featuring a seal to create an axial seal with the housing, reducing the need for integral plastic covers and promoting recyclable components, while the lower support ring may or may not include a seal, allowing for efficient airflow and reduced waste generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If injection-molded plastic components are used for covers and housings, then ease of filter element replacement and alignment is improved, but cost and environmental impact worsen
Solution Approach 1:
The patent removes the injection-molded plastic cover component entirely from the filter element design. Instead, it uses a simple wire screen assembly that can be easily inserted and removed from the housing without requiring molded plastic parts for alignment or sealing, thereby eliminating the associated costs and environmental concerns while maintaining ease of replacement
Solution Approach 2:
The patent changes the material parameter from injection-molded plastic to wire screen material. This parameter change eliminates the need for complex molding processes, reduces production cost, and improves environmental sustainability while the wire screen design maintains functional performance for filtration and alignment
2Ease of operation
If injection-molded plastic components are used for covers and housings, then ease of filter element replacement is improved, but environmental impact worsens
Solution Approach 1:
The patent extracts and eliminates the injection-molded plastic cover from the design, replacing it with a wire screen assembly that generates minimal non-biodegradable waste. The wire screen and support rings can be easily separated and recycled, significantly reducing environmental impact while maintaining ease of filter element replacement
Solution Approach 2:
The patent enables easy discarding and recovering of components by using a simple wire screen design without integrated plastic covers. The wire screen can be removed and replaced independently, and the support rings can be recovered and reused, reducing waste generation and improving environmental sustainability
3Reliability
If seal is included on lower support ring, then sealing performance is improved, but device complexity increases
Solution Approach 1:
The patent applies sealing only where necessary - the upper support ring includes a seal for sealing performance, while the lower support ring intentionally omits a seal to reduce complexity. This local differentiation of sealing quality maintains reliability where needed while minimizing device complexity overall
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 design reduces production costs and environmental impact by allowing reusable components, enhances filtration efficiency, and minimizes waste through the use of recyclable materials and reduced plastic usage, while maintaining effective air filtration performance.
Implementation Method 1
compressing the seal member between a sealing surface of the filtration system housing and the upper support ring to form an axial seal
Implementation Method 2
the intake air is typically passed through a filter element to remove particulate (e.g., dust) from the intake air prior to combustion
Data Source
AI summary
An axial flow air filter system is described. The system includes an axial flow filter element having a filter media. The filter media includes an inlet face and an outlet face, the inlet face spaced apart from the outlet face. The axial flow filter element includes an upper support ring adjacent to the inlet face of the filter media. The upper support ring circumscribes the filter media and supports an upper seal. The upper seal forms a seal with a housing when the filter element is received in the housing. The axial flow filter element further includes a lower support ring adjacent to the outlet face of the filter media. The lower support ring circumscribes the filter media. In some arrangements, the lower support ring does not include a seal.