Extruded Profile Filter Frame for Cabin Air

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Solution Overview

Problem

Existing filter elements for interior air filtration, particularly in vehicles, are complex and costly to manufacture, making it difficult to produce filter elements in small batches and adjust shapes quickly, as they require expensive injection molds and complex assembly processes.

Innovation Solution

A filter element composed of extruded profile strips, which allows for the creation of mechanically stable and cost-effective filters of various sizes, featuring multiple layers (pre-filter, fine filter, and adsorption filter) with a frame design that eliminates the need for additional seals and enables easy assembly, using materials like ABS, PP, PA, or aluminum, and incorporating inward protruding shoulders and adhesive webs for secure gluing and a peripheral flange for sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If injection-molded frames are used for filter elements, then sealing and structural integrity are improved, but manufacturing complexity and costs increase significantly

Engineering Contradiction:

ImprovesealingVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filter element is divided into separate modular components: a frameless filter medium assembly and a separate gasket. The filter medium is folded into a compact package and held together by corner members, while sealing is achieved through a separate gasket that engages with the housing. This segmentation eliminates the need for complex injection-molded frames while maintaining sealing integrity.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If injection-molded frames are used for filter elements, then structural stability is improved, but production costs and mold requirements increase

Engineering Contradiction:

Improvestructural stabilityVSAvoidproduction cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner members serve multiple functions: they hold the folded filter medium in place, provide structural support at critical corners, and engage with the housing to position the filter element correctly. This multi-functionality replaces the need for complex injection-molded frames while reducing manufacturing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If injection-molded frames are used for filter elements, then frame strength is improved, but adaptability to different sizes and shapes decreases

Engineering Contradiction:

Improveframe strengthVSAvoidadaptability to different sizes

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The filter element design allows the filter medium to be folded and configured in different arrangements to suit various housing sizes and shapes. The corner members and gasket provide the necessary structural support and sealing, while the filter medium itself can be adapted to different dimensions without requiring new injection molds. This dynamic configurability enables production of filter elements in small batches with varying dimensions.

Inventive Principle:

Principle #15Dynamics

4Reliability

If multiple separate filter layers are assembled with additional seals, then filtration effectiveness is improved, but assembly complexity increases

Engineering Contradiction:

Improvefiltration effectivenessVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple filter layers (pre-filter, fine filter, and activated carbon layer) are combined into a single folded filter medium package. The different filtration functions are integrated into one continuous folded structure, held together by corner members, eliminating the need for separate seals between layers and simplifying assembly while maintaining effective multi-stage filtration.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution simplifies the manufacturing process, reduces production costs, and allows for quick assembly and sealing of the filter element, ensuring effective air filtration and separation between the raw and clean gas sides, while being adaptable to different sizes and shapes without the need for specialized molds.

Implementation Method 1

an adsorption filter layer with activated carbon

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

a fine filter layer, in particular for separating aerosols

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentEP3520878B1Filter element and use of such a filter element

Publication Date: 2020.11.04 CARL FREUDENBERG KG

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AI summary

The invention relates to a filter element for filtering interior air with at least two filter layers (1, 2, 3), wherein the filter layers (1, 2, 3) are arranged in a frame (4). According to the invention, the frame (4) is composed of extruded profile strips (5). Advantageously, the filter element has a simple structure and allows for easy installation in a housing. The filter element can also be manufactured cost-effectively in small batches in a wide variety of sizes. The invention also relates to the use of such a filter element for filtering the cabin air in a vehicle.