Filter Element Notch and Wing Support for Correct Installation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing filter elements for internal combustion engines, particularly in commercial vehicles, face challenges in simple exchange and correct positioning due to their large size and the risk of damage during installation, especially when incorrectly positioned.

Innovation Solution

A filter element design featuring a filter bellows with notches and a support structure with radially oriented wings integrated into the end disk, which reinforces the end disk and prevents deformation during installation, ensuring correct positioning and reducing the risk of damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of moving object

If a filter element with large size is used for commercial vehicles, then the filter surface area is increased, but the installation space requirement increases and exchange becomes difficult

Engineering Contradiction:

Improvefilter surface areaVSAvoidinstallation space

Core Design Contradiction:

Area of moving objectVSVolume of moving object

Solution Approach 1:

The filter element is designed with a nested structure where the filter bellows is arranged around a support pipe, creating a compact concentric configuration. The end disks are positioned at both ends of the support pipe, with the filter media folded in a star shape surrounding the longitudinal axis, maximizing filter surface area within minimal installation space.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The filter media is folded in a star shape around the longitudinal axis, transforming a two-dimensional filter surface into a three-dimensional radial configuration. This allows the filter surface to extend in multiple directions from the central support pipe, increasing effective filtering area without proportionally increasing the overall length or volume of the filter element.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If a conventional filter element without reinforcement is used, then the structure is simpler, but the end disk deforms under compression during installation

Engineering Contradiction:

Improvestructural simplicityVSAvoidend disk deformation

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The support structure with radially oriented wings is pre-integrated into the end disk at both sides of the notch before installation. This preliminary reinforcement prevents deformation during the installation process by providing structural support that resists compressive forces applied to the end disk during mounting.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The end disk is designed as a composite structure combining the base end disk material with an integrated support structure featuring radially oriented wings. This composite configuration provides both the sealing function of the end disk and the structural reinforcement needed to prevent deformation under compression during installation.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If a filter element without positioning features is used, then the structure is simpler, but correct positioning in the housing cannot be ensured

Engineering Contradiction:

Improvestructural simplicityVSAvoidpositioning accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

A notch is introduced as an asymmetric feature in the filter bellows at one end, which interacts with a corresponding counter element in the housing. This asymmetric positioning feature ensures that the filter element can only be installed in the correct rotational orientation, preventing incorrect positioning while maintaining overall structural simplicity.

Inventive Principle:

Principle #4Asymmetry

4Device complexity

If the filter bellows folds are exposed without protection, then the structure is simpler, but the folds are vulnerable to damage during installation

Engineering Contradiction:

Improvestructural simplicityVSAvoidfold protection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The support structure with radially oriented wings is positioned to provide protective support to the filter bellows folds before installation forces are applied. The wings extend radially outward and provide a cushioning effect that prevents direct impact or excessive compression on the delicate folded filter media during the installation process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20250339804A1Filter element, housing for a filter system, and filter system comprising a filter element and a housing

Publication Date: 2025.11.06 MANN HUMMEL GMBH

AI summary

A filter element for filtering a fluid has a support pipe and a filter bellows arranged about a longitudinal axis on the support pipe. The filter bellows has folds with radially outer fold edges. The filter bellows has a first axial end and a second oppositely positioned axial end. The filter bellows has a notch at least at one of the first and second axial ends. An axial length of the notch in longitudinal direction is shorter than a longitudinal extension of the filter bellows. The support pipe has a support structure at the axial end with the notch and has at least two wings. The support structure is oriented radially away from the support pipe and is integrated into the end disk at both sides of the notch. A filter system with such a filter element arranged in a housing is provided.