Cast Formed Filter for Compact Air Induction Housing
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Solution Overview
Problem
Air induction housing systems face challenges in reducing size and creating unique shapes without compromising filtration capacity, due to space constraints in vehicular applications, leading to smaller filters with reduced performance and increased manufacturing complexity.
Innovation Solution
A cast formed filter with a unique configuration of inlet and outlet openings, manufactured using a molding process that accommodates non-uniform shapes and sizes, providing a high filtration capacity while maintaining fluid flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing size is reduced to meet space constraints, then the filter size is reduced, but the filtration capacity is reduced
Solution Approach 1:
The patent transitions from conventional two-dimensional filter media to three-dimensional cast formed filter media with depth. The filter media includes a three-dimensional periphery with inlet openings and outlet openings extending into the media, creating internal fluid paths that utilize the third dimension (depth) for filtration. This allows increased filtration capacity within a compact housing volume by exploiting the depth dimension rather than relying solely on surface area.
Solution Approach 2:
The patent implements nested fluid paths where multiple outlet openings are positioned within or adjacent to inlet openings, and multiple fluid paths are nested within the three-dimensional filter media. The second portion of filter media is disposed between outlet openings and the inlet end, nesting filtration layers within each other to maximize filtration capacity in a compact configuration.
2Shape
If the housing is given a unique shape to optimize space, then the filter must be made in a unique configuration, but the manufacturing complexity increases
Solution Approach 1:
The patent replaces conventional mechanical filter manufacturing processes (such as folding, sealing, and assembly of multiple components) with a casting process. The filter media is formed by casting material into a mold that defines the three-dimensional periphery, inlet openings, outlet openings, and internal fluid paths in a single operation. This substitution of the manufacturing mechanism enables complex unique shapes to be produced without proportionally increasing manufacturing complexity.
Solution Approach 2:
The casting process serves multiple functions simultaneously: it forms the three-dimensional periphery, creates inlet and outlet openings, defines internal fluid paths, and structures the filter media architecture all in a single manufacturing step. This multi-functionality of the casting process allows the filter to achieve unique configurations optimized for specific housing spaces without requiring multiple specialized manufacturing operations.
3Volume of moving object
If smaller filters are used to fit restricted spaces, then the airflow capacity is reduced, but the system performance is compromised
Solution Approach 1:
The patent creates multiple fluid paths that extend through the three-dimensional filter media, allowing airflow to be distributed through multiple parallel channels. The inlet openings and outlet openings are arranged to create numerous fluid paths through the filter media, effectively increasing the total airflow capacity despite the compact filter size. This utilizes the depth dimension to create multiple flow channels that would not be possible in conventional two-dimensional filters.
Data Source
AI summary
A cast formed filter and a method for making the filter are provided. The cast formed filter includes a cast formed filter media having an inlet end, an outlet end, a plurality of inlet openings, a plurality of outlet openings, and a fluid path. The plurality of inlet openings extend from the inlet end into the cast formed filter media, wherein a first portion of the cast formed filter media is disposed between each of the plurality of inlet openings and the outlet end. The plurality of outlet openings extend from the outlet end into the cast formed filter media, wherein a second portion of the cast formed filter media is disposed between each of the plurality of outlet openings and the inlet end, the second portion comprising at least a portion of the first portion of cast formed filter media. The fluid path extends through at least one of the plurality of inlet openings and through at least one of the plurality of outlet openings, wherein fluid flowing through the fluid path is filtered by the cast formed filter media.