Cross-flow filter media with inter-channel openings
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Solution Overview
Problem
Existing filter media constructions for internal combustion engines face issues with clogging due to foreign particulates and larger contaminants, which reduce their filtering efficiency and holding capacity, potentially blocking fluid flow and degrading engine performance.
Innovation Solution
A filter media design featuring a first and second sheet with defined fluid channels and surface irregularities that allow uninterrupted fluid flow between channels, created by embossments and irregularities, enhancing the removal of foreign particulates and maintaining efficiency even when clogged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If filter media collects substantial amount of foreign particulates in continuous fluid flow channels, then filtering capacity increases, but clogging occurs and holding capacity is reduced
Solution Approach 1:
The filter media is divided into multiple discrete fluid channels (first fluid channel, second fluid channel, etc.) formed between pleats. This segmentation allows particulates to be distributed across multiple channels, preventing any single channel from becoming completely blocked and maintaining filtering capacity as particulates accumulate.
Solution Approach 2:
The filter media uses a pleated structure that extends filtering surface area in a third dimension. The pleats create multiple channels and increase the available filtering surface area without increasing the frontal area of the filter, allowing greater holding capacity while maintaining flow paths.
2Object-affected harmful factors
If larger contaminants block end of filter media, then fluid flow is prevented, but filtering of smaller particulates is compromised
Solution Approach 1:
Multiple discrete fluid channels provide alternative flow paths. If one channel becomes blocked by larger contaminants, fluid can continue to flow through other channels, maintaining overall productivity and preventing complete flow cessation.
Solution Approach 2:
The filter media incorporates varying channel dimensions and configurations throughout its structure. Some channels are designed with different cross-sectional areas or lengths, allowing fluid to adaptively redirect through channels with more favorable flow parameters when blockages occur.
3Ease of manufacture
If filter media structure is simplified, then manufacturing ease increases, but ability to prevent clogging is reduced
Solution Approach 1:
The filter media uses thin pleated sheets that can be manufactured through forming processes. These flexible thin films are capable of creating complex multi-channel structures through pleating and folding, achieving clogging resistance without requiring complex rigid structures or multiple assembly steps.
Data Source
AI summary
A filter media including a first sheet having an inner surface and an outer surface, a second sheet having an inner surface and an outer surface, wherein the inner surface of the first sheet and the inner surface of the second sheet at least in part define at least two fluid channels between the first sheet and the second sheet to define a filter media having a first axial end and a second axial end, wherein the at least two fluid channels extend between the first axial end and the second axial end, and wherein, interior to said axial ends, the first and second sheets define at least one opening between a first one of said at least two fluid channels and a second one of said at least two fluid channels such that fluid can uninterruptedly flow between the first one of said at least two fluid channels and the second one of the at least two fluid channels, and further wherein the at least two fluid channels and the at least one opening are at least defined in part by a surface characteristic of the first sheet and a surface characteristic of the second sheet.