Diesel Fuel Pre-Filtering System with Segmented Filtration
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Solution Overview
Problem
Current diesel fuel pre-filtering systems are inefficient in removing water and contaminants, prone to saturation, costly, and difficult to assemble and replace, with fragile translucent components and single filtration stages that can allow water to pass through, leading to engine damage and high production costs.
Innovation Solution
A pre-filtering system composed of thermoplastic materials with multiple filtration stages, an integrated inspection window for water drainage, and a permanent bond between components for easy assembly and replacement, featuring a hydrophobic membrane for water removal and a retention valve to prevent fuel loss during replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single coalescing filtration means is used in the pre-filter, then the structure is simple and cost-effective, but the filtration efficiency decreases when the surface becomes saturated with contaminants
Solution Approach 1:
The pre-filter is divided into multiple independent filtration areas (first coalescing filtration area, second coalescing filtration area, and hydrophobic filtration area) that work in sequence. Each area handles specific filtration tasks, preventing surface saturation and maintaining continuous filtration efficiency throughout the service life of the filter.
Solution Approach 2:
Different filtration mechanisms are applied to different areas of the pre-filter. The first and second coalescing filtration areas use coalescing material for initial water separation, while the hydrophobic filtration area uses hydrophobic material for final water removal. This localized application of different filtration qualities ensures optimal performance at each stage.
2Ease of operation
If a translucent inspection window is made from thermoplastic material to allow visibility, then the inspection function is enabled, but the component becomes fragile and prone to breaking during replacement
Solution Approach 1:
The inspection window is created by using a translucent thermoplastic material specifically for the housing structure where visibility is needed, while other structural components use more robust thermoplastic materials. This localized application of translucency provides inspection functionality without compromising the overall structural strength of the pre-filter assembly.
3Strength
If the pre-filter housing is made from metal material with single separation stage, then the structural strength is high, but the production cost and scrap cost increase significantly
Solution Approach 1:
The housing material is changed from metal to thermoplastic material, representing a parameter change in material selection. This substitution maintains sufficient structural strength for the pre-filter application while dramatically reducing both production costs and scrap disposal costs, as thermoplastic materials are cheaper to manufacture and recycle compared to metal materials.
4Ease of repair
If the translucent element is removed periodically to replace the filtering component, then the filtering component can be replaced, but the translucent element breaks and loses translucence over time
Solution Approach 1:
The translucent inspection window is permanently integrated into the housing structure through welding, merging two previously separate components (the translucent element and the housing) into a single unified structure. This eliminates the need to remove or detach the translucent element during filter replacement, preventing breakage and loss of translucence while maintaining ease of filtering component replacement.
Solution Approach 2:
Instead of using a removable translucent element that degrades, the inspection function is permanently incorporated into the housing structure itself through welding. The housing structure serves as both the protective enclosure and the inspection window, eliminating the need for separate replaceable translucent components.
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
Ensures efficient filtration, prevents water from reaching the fuel supply line, simplifies maintenance and replacement, reduces production costs, and enhances the durability and visibility of the inspection window for user maintenance, thereby extending engine service life and ensuring reliable operation.
Implementation Method 1
a first filtering area defining a restriction connecting between the fuel inlet area and a subsequent filtering area
Implementation Method 2
a second filtering area defining a restriction connecting between a preceding filtering area and the fuel outlet area
Implementation Method 3
the structure (2) and the inspection window (3) being composed of thermoplastic materials distinct from each other and connected to each other by a permanent bond
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention pertains to the field of automotive engineering, and relates to a diesel fuel pre-filtering system, more specifically of pre-filtering, for diesel oil, to be used in internal combustion engines operating on a diesel cycle. The diesel fuel pre-filtering system (1) is equipped with: (a) a structure (2) for housing at least two filtering areas; a fuel inlet area (4); a fuel outlet area (5); and (b) an inspection window (3) equipped with a drain (8) for water,with: (i) a first filtering area defining a constraint connecting between the fuel inlet area and a subsequent filtering area; (ii) a second filtering area defining a constraint connecting between a preceding filtering area and the fuel outlet area; and (iii) the structure (2) and the inspection window (3), composed of thermoplastic materials, distinct from each other, and connected to each other by means of a permanent bond.