Filter Element With Flexible Film And Recessed End Plate
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Solution Overview
Problem
Conventional air filter systems for internal combustion engines face issues with turbulence at the air intake, which can damage the filter media and lead to premature clogging, and existing solutions require additional protective structures that increase complexity and cost.
Innovation Solution
A filter element with a zigzag folded filter body and a flexible, impermeable film on its outer surface acting as both inflow and grip protection, designed to deflect airflow tangentially and reduce flow resistance, while also serving as a handle for easy assembly and disassembly, thus preventing damage to the filter medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing incorporates an internal structure to prevent turbulence stress on the filter medium, then the filter medium is protected from damage, but the device complexity increases
Solution Approach 1:
The patent combines the protective function with the handle function into a single integrated component. The recess in the end plate serves both as a protective structure against turbulence and as a handle for filter element replacement, eliminating the need for separate protective structures and reducing device complexity.
Solution Approach 2:
The recess structure in the end plate performs multiple functions simultaneously: it protects the filter medium from turbulence during operation, provides a gripping area for easy filter element replacement, and maintains structural integrity. This multi-functionality resolves the contradiction by avoiding additional complexity.
2Productivity
If the airflow is directed towards the folded paper medium at the inlet, then the pre-cleaning process is enhanced, but the filter medium becomes clogged and damaged prematurely
Solution Approach 1:
The patent applies a protective coating specifically to the area of the filter medium that is exposed to the inlet airflow. This localized protection allows the airflow to continue directing coarse particles for pre-cleaning while the coated area resists clogging and damage, maintaining both productivity and reliability.
3Reliability
If a lining with screen arrangement is added to protect the filter element, then the filter medium is protected from direct flow, but the manufacturing cost and complexity increase
Solution Approach 1:
The protective function is integrated directly into the end plate structure through a recess that is molded or formed as part of the end plate itself. This eliminates the need for separate lining and screen arrangement components, reducing manufacturing steps and costs while maintaining protection against direct flow.
Solution Approach 2:
The end plate's own structure provides the protection it needs. The recess in the end plate creates a turbulence-free zone that protects the filter medium without requiring additional protective components, making the system self-sufficient and easier to manufacture.
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 effectively pre-separates coarser dust particles through cyclone action, reduces wear on the filter medium, and allows for efficient and cost-effective production and replacement of the filter element, enhancing the filter's service life and operational safety.
Implementation Method 1
designed to deflect airflow tangentially and reduce flow resistance, while also serving as a handle for easy assembly and disassembly, thus preventing damage to the filter medium
Data Source
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AI summary
The invention relates to a filter element (10) comprising a filter body (12) with a longitudinal axis (L), the inner and outer surface (22) of which is permeable to a medium to be filtered, in particular air, a first open or closed end disk (16) arranged on one end face (15), and a second end disk (18) arranged on the opposite end face (17), wherein the outer surface (22) of the filter body (12) has at least one fluid-tight region (60) that is impermeable to the medium to be filtered. The invention further relates to a filter system (100) for the replaceable installation of such a filter element (10).