Coiled Z-Filter Media With Cured Seal Grid
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Solution Overview
Problem
Existing air cleaner systems face challenges in effectively removing particulate material from gas streams, particularly in engine combustion air, leading to potential damage within internal mechanisms, and existing z-filter media constructions face issues with sealing and maintaining high-quality seals at flute ends.
Innovation Solution
The development of a z-filter media construction using a corrugated sheet and a facing sheet, coiled into a media pack with a preform and grid arrangement, where a region of cured seal material secures the grid to one flow face, and a winding bead is applied to close the coil, enhancing sealing and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If z-filter media constructions are used for particulate removal, then filtering efficiency is improved, but sealing quality at flute ends deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the media pack with integrated end seals and flute end closures before installation. The seal material is positioned and cured in advance to ensure proper sealing geometry is established prior to the filter experiencing operational stresses, preventing seal degradation at flute ends.
Solution Approach 2:
The patent employs composite materials by combining the z-filter media construction with integrated seal materials and structural support elements. The composite structure integrates the filtering media with sealing compounds and rigid support frameworks to maintain both high filtering efficiency and seal integrity at flute ends simultaneously.
2Volume of moving object
If the media pack is coiled into a compact configuration, then space efficiency is improved, but structural integrity deteriorates
Solution Approach 1:
The patent applies spheroidality by coiling the flat z-filter media into a cylindrical or spiral three-dimensional configuration. This curvature transforms the two-dimensional media into a compact volumetric structure while the continuous coiled geometry naturally distributes mechanical stresses, maintaining structural integrity despite the compact form factor.
Solution Approach 2:
The patent employs dimensionality change by transitioning the media from a flat two-dimensional plane to a three-dimensional coiled structure. This adds spatial efficiency by utilizing vertical and radial dimensions, compacting the media volume while the multi-layered coiled architecture provides inherent structural reinforcement through distributed load paths.
3Reliability
If a winding bead is applied to close the coil, then sealing effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining the winding bead sealing operation with the media pack coiling process into a single integrated manufacturing step. The bead application, coiling, and sealing operations are performed sequentially without interruption, eliminating the need for separate sealing stations and reducing overall manufacturing complexity despite the added sealing function.
Solution Approach 2:
The patent employs self-service by designing the winding bead application process to automatically perform multiple functions: the bead material itself serves as both the sealing compound and the binding agent that holds the coiled structure together. The process self-regulates the seal placement and curing without requiring additional manual intervention or complex control systems.
Data Source
AI summary
A one aspect method of forming filter cartridge arrangements for use in air cleaners is provided. The method involves coiling a media pack with a central winding bead and cutting through the winding bead in the coiled media pack to form two media packs. An example filter arrangement is disclosed. In another aspect, a filter cartridge arrangement for use in air cleaners is provided. The filter cartridge arrangement includes a media pack including a plurality of inlet flutes and outlet flutes extending between first and second opposite flow faces and formed from an arrangement of facing sheet secured to corrugated sheet. An example cartridge includes a preform secured to the media pack. In some forms, the preform includes a grid arrangement extending across one of the flow faces. The grid arrangement can include a region of cured seal material positioned in contact with the first flow face, to secure the grid arrangement to the flow face.