Compact Filter Ultrasonic Welding Pressure Loss Reduction
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Solution Overview
Problem
Existing compact air filters for motor vehicles face challenges in achieving optimal filtration efficiency and service life due to material limitations, such as pressure losses and layer detachments caused by adhesives and vibrations, which affect their performance and reliability.
Innovation Solution
A compact filter element is created using a composite filter medium web comprising a synthetic material, like meltblown layers, and a non-synthetic material, such as cellulose, which are ultrasonically welded together, eliminating the need for separate adhesives and enhancing strength and filtration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to connect filter medium webs, then connection is achieved, but pressure losses increase due to longitudinal traces constricting channels
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with an ultrasonic welding process that uses mechanical vibration and heat to fuse the filter medium webs directly. This substitution eliminates adhesive traces that would otherwise constrict gas channels and cause pressure losses, while maintaining strong connections between the smooth and corrugated filter medium layers.
Solution Approach 2:
The ultrasonic welding process utilizes phase transitions (melting and solidification) of the filter medium material during welding. The intense ultrasonic vibration generates localized heat that melts the material at the interface, allowing the layers to fuse together. Upon cooling, the material solidifies to form a strong bond without requiring adhesive, thus avoiding channel constriction and pressure losses.
2Ease of manufacture
If conventional filter materials are used, then manufacturing is simple, but service life is reduced due to layer detachments from vibrations
Solution Approach 1:
The patent employs composite filter medium webs combining different materials (e.g., cellulose and synthetic fibers) in a single integrated structure. This composite construction enhances the overall mechanical strength and vibration resistance of the filter medium, preventing layer detachments during vehicle operation. The different materials complement each other's properties, providing both ease of manufacture through ultrasonic welding and improved reliability under vibrational stress.
3Reliability
If dense filter media with fine pores are used, then filtration efficiency increases, but pressure losses increase
Solution Approach 1:
The patent applies local quality by using corrugated filter medium with varying density zones. The corrugation structure creates regions of different pore sizes and flow characteristics within the same filter medium. This allows the filter to achieve high filtration efficiency in certain zones while maintaining lower pressure losses in others, optimizing the overall performance by having different local regions serve different functions.
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 solution minimizes pressure losses, prevents layer detachments, and extends the service life of the filter by combining the advantages of synthetic and non-synthetic materials, providing improved filtration efficiency and stability, especially in the presence of vibrations.
Implementation Method 1
at least one smooth filter medium web and one corrugated filter medium web are placed on top of one another and connected to one another at least in regions by means of ultrasonic welding
Data Source
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AI summary
The invention relates to a compact filter, particularly a compact air filter for motor vehicles, comprising a compact filter element for the replaceable use in a filter housing, and to a method for producing a compact filter. The compact filter element comprises a filter body made of web-shaped filter medium (18). The web-shaped filter medium (18) is composed of at least one smooth filter medium web (20) and one undulated filter medium web (22) that are placed on top of each other and at least connected in some areas by means of ultrasonic welding. At least one of the filter medium webs (20, 22) consists of a compound made of at least two components. At least one of the components is a synthetic material (48) and at least one of the components is a non-synthetic material (46).