Embossed Filter Media Packs with Curved End Cap Support
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Solution Overview
Problem
Existing filter cartridges for engine air filters face capacity limitations and reliability issues due to deformation under high differential pressures, and conventional end caps with flat inner surfaces restrict inlet flow faces and require complex bonding methods.
Innovation Solution
A filter cartridge design with non-planar end caps and a matching curved or multifaceted geometry that supports pleat packs, allowing for a large inlet flow face and enhanced structural support, using adhesive end walls and a frame to secure the media pack, with options for rigid or liquid potting compounds for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional flat end caps are used, then the bonding process is simplified, but the inlet flow face area is reduced and structural support is limited
Solution Approach 1:
The end caps are designed with curved inner surfaces that match the curved outer surfaces of the filter media pack ends. This curvature allows the end caps to conform to the rounded geometry of the pleat pack, maximizing the inlet flow face area while providing structural support without requiring complex bonding procedures.
2Reliability
If support structure is added to prevent deformation, then reliability under high differential pressure is improved, but the inlet flow face area is reduced
Solution Approach 1:
The support structure is nested within the end caps rather than being placed at the inlet flow face. The end caps themselves serve as the support structure, with their curved geometry providing reinforcement to the filter media pack ends, thereby preventing deformation under high differential pressure while maintaining a large inlet flow face area.
3Ease of manufacture
If liquid potting material is used for bonding, then assembly is simplified, but manufacturing time increases due to curing requirements
Solution Approach 1:
The patent employs heat-activated adhesive strips instead of liquid potting materials requiring curing. These adhesive strips are applied to the outer surfaces of the end caps and activated by heat during assembly, providing immediate bonding without the need for extended curing time. The adhesive strips are consumed in the process, similar to disposable bonding elements.
4Area of stationary object
If the filter media pack ends are made non-planar with bulged faces, then structural support and flow face area are maximized, but the bonding complexity increases
Solution Approach 1:
The filter media pack ends are designed with asymmetric bulged faces that protrude from the sides, creating non-planar surfaces. The end caps are correspondingly designed with curved inner surfaces that match this asymmetric geometry. This asymmetric design maximizes the inlet flow face area while the matching curved surfaces simplify the bonding process by providing conformal contact areas.
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
The design provides improved structural support, maximizes inlet flow face, and reduces manufacturing complexity while ensuring effective filtration without capacity restrictions, enhancing reliability and ease of assembly.
Implementation Method 1
a first adhesive end wall embedded into the first bulged face of the first end
Data Source
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AI summary
A filter cartridge (10) is provided. The filter cartridge (10) includes a pack of filter media (12) having an inlet face (16) and an outlet face (18). The filter media pack (12) further includes opposite first and second sides (20, 22) and opposite first and second ends (24, 26). The sides (20, 22) and ends (24, 26) extend transversely between the inlet and outlet faces (16, 18). The sides (20, 22) also extend transversely between the ends (24, 26) such that each end has an external non-planar, curved or multifaceted geometry. The filter cartridge (10) further includes a pair of end caps (46, 48) located against each end (24, 26) of the filter media pack (12). Each end cap (46, 48) has an internal surface with a geometry closely matching the geometry of the associated filter media pack end. Further, an adhesive (94) is disposed between the filter media pack (12) and the end caps (46, 48) to secure them together.