Curved Panel Filter Element for Compact Engine Air Intake
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Solution Overview
Problem
Conventional panel-type air filter elements with planar inlet and outlet faces occupy significant space due to their flat and rigid design, posing a challenge in engine compartments where space is limited.
Innovation Solution
The development of filter elements with non-planar inlet and outlet faces and curvilinear seal members, allowing for flexible or rigid configurations that can conform to the shape of a filtration system housing, reducing spatial constraints and improving dust loading characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If planar inlet and outlet faces are used in panel-type air filter elements, then manufacturing is simplified, but spatial requirements increase significantly
Solution Approach 1:
The patent applies curvature by forming the inlet and outlet faces of the filter element in a non-planar configuration. Specifically, the inlet face is formed with a first curvature and the outlet face with a second curvature, allowing the filter element to conform to curved surfaces in the filtration system housing. This curved geometry reduces the spatial volume required compared to traditional planar designs while maintaining manufacturing feasibility through appropriate molding techniques.
2Volume of moving object
If non-planar inlet and outlet faces are used, then spatial requirements are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the seal member with the pleated filter media to form an integrated assembly. The seal member is molded directly onto the pleated media pack, creating a unitary structure that eliminates separate sealing components. This integration simplifies the manufacturing process by reducing the number of assembly steps and components, thereby offsetting the increased complexity introduced by the non-planar face geometries.
3Ease of manufacture
If planar gasket sealing surface is used, then manufacturing is easier, but space consumption increases
Solution Approach 1:
The patent applies curvature to the seal member to match the non-planar inlet and outlet faces. The seal member is formed with a curvilinear geometry that conforms to the curved surfaces, enabling the filter element to achieve compact spatial configuration while maintaining effective sealing contact with the housing surfaces.
4Adaptability or versatility
If curvilinear seal members are used, then adaptability to housing shape improves, but manufacturing precision requirements increase
Solution Approach 1:
The seal member is molded directly onto the pleated filter media in an integrated manufacturing process. This merging of components allows the curvilinear geometry to be formed in a single molding operation, reducing the need for separate precision machining or assembly steps that would otherwise be required to achieve the same level of geometric accuracy.
Data Source
AI summary
Panel filter elements having a pleat block and a seal member are described. The panel filter elements are arranged such that the seal members and pleat blocks can have curved and/or angled elements. The seal member of a filter element may be curved, angled, twisted, and/or has a varying cross-section. The inlet and outlet faces of the pleat block of the filter element may be curved and/or twisted instead of planar. In some arrangements, both the seal member of the filter element and the faces of the pleat blocks can be curved and/or twisted. The described filter elements may be may be flexible, such that the shape of the filter element and/or seal can conform to the shape of a filter housing, or rigid, such that the shape of the filter element remains substantially the same before and after installation into a filter housing.