Engine Air Filter Element With Nonwoven Pre-Filter and Tapered Edges
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Solution Overview
Problem
Existing engine air filter assemblies face a continuous need for improvement in air filtration efficiency, particularly in the integration and securing of nonwoven pre-filter elements within the filter housing to prevent pinching and ensure proper air flow.
Innovation Solution
A method of assembling the engine air filter assembly involves securing the secondary filter material to the primary filter material using glue beads, ensuring the secondary filter material is not pinched between the housing and the peripheral seal, with tapered lateral edges and rounded corners to facilitate insertion and prevent pinching, and using a support member to counteract fluid flow forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the secondary filter material is secured to the primary filter material using glue beads, then the structural integrity and sealing are improved, but the risk of pinching between housing and peripheral seal increases
Solution Approach 1:
The peripheral seal is pre-formed with recesses that receive the secondary filter material before assembly. This preliminary positioning ensures the secondary filter material is secured to the primary filter material using glue beads while preventing pinching between the housing and seal during assembly.
Solution Approach 2:
The peripheral seal acts as an intermediary component with integrated recesses that mediate between the secondary filter material and the housing. These recesses provide a controlled environment for securing the secondary filter material while eliminating the pinching hazard.
2Ease of operation
If the filter element is designed with tapered lateral edges and rounded corners, then the ease of insertion into housing is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The filter element incorporates rounded corners instead of sharp angles, which facilitates easier insertion into the housing by reducing stress concentrations and improving guidance during assembly. The curvature is applied consistently across all corners of the filter element.
Solution Approach 2:
The filter element features tapered lateral edges that create an asymmetric profile optimized for insertion direction. The tapering angle is specifically designed to guide the filter element into the housing while maintaining structural integrity, balancing ease of insertion with manufacturing feasibility.
3Reliability
If the support member is added to counteract fluid flow forces, then the reliability of air flow maintenance is improved, but the device complexity increases
Solution Approach 1:
A support member is introduced as a counterbalancing element that opposes the forces generated by fluid flow. This support member is strategically positioned to counteract bending and deformation forces, maintaining reliable air flow through the filter element while managing the added complexity through functional integration.
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 solution enhances the structural integrity and filtration efficiency by preventing pinching of the secondary filter media, ensuring proper sealing and maintaining air flow, while providing a method for easy assembly and insertion of the filter element into the housing.
Implementation Method 1
securing a first portion of the secondary filter material to an intake face of a primary filter material with at least a first glue bead
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A filter element for an air filter assembly of an engine includes a primary filter media and a secondary filter media. The primary filter media has a plurality of pleats having first fold edges on an inlet face of the primary filter media and second fold edges on an outlet face of the primary filter media. The first and second fold edges extend from a first lateral side to a second lateral side of the primary filter media. The secondary filter media is constructed of a non-woven material and includes a first portion arranged on the inlet face of the primary filter media, a second portion secured to the first lateral side of the primary filter media, and a third portion secured to the second lateral side of the primary filter media.