Flat-Filter Element Assembly for Sealed Multi-Stage Air Filtration
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Solution Overview
Problem
Fuel cell systems require cost-effective and service-friendly filter elements that can efficiently filter air by combining particle and gas filtration, while existing solutions often lack stability and effective sealing, leading to inefficiencies in adsorption capacity and pressure drop.
Innovation Solution
A flat-filter filter element with an overmolded plastic frame and a circumferential cast element connects two filter medium bodies in a fuel cell system, providing a stable and sealed arrangement for fluid flow, eliminating the need for lateral bands and enhancing stability and sealing against side flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple filter medium bodies are arranged adjacent to each other in an axial direction, then adsorption capacity and dust capacity are improved, but device complexity and sealing reliability worsen
Solution Approach 1:
The patent combines multiple filter medium bodies (particle filter and adsorption filter) into a single integrated filter element with a common frame structure. The frame integrates sealing elements and mounting features that seal the entire multi-stage filter assembly as one unit, rather than requiring separate sealing arrangements for each filter stage.
Solution Approach 2:
The frame structure serves multiple functions simultaneously: it provides structural support for multiple filter medium bodies, integrates sealing elements to prevent side flows, provides mounting connections to the housing, and creates sealed chambers for each filter stage. This multi-functional design simplifies the overall structure while maintaining reliable sealing.
2Quantity of substance
If multiple filter medium bodies are arranged adjacent to each other in an axial direction, then adsorption capacity and dust capacity are improved, but manufacturing complexity worsens
Solution Approach 1:
The frame is pre-manufactured with integrated sealing elements and mounting features before the filter medium bodies are installed. This preliminary preparation of the frame structure simplifies the final assembly process, allowing multiple filter stages to be quickly installed without complex sealing operations.
Solution Approach 2:
The filter medium bodies are nested within the frame structure in a compact axial arrangement. The frame contains and organizes multiple filter stages in a space-efficient manner, with each filter medium body positioned within the common frame structure, simplifying both manufacturing and assembly.
3Reliability
If frame seals against housing, then sealing against side flows is improved, but pressure drop increases
Solution Approach 1:
The sealing elements are positioned locally at critical areas where side flows would occur, such as at the interface between the frame and housing, and at the boundaries between different filter stages. This localized sealing approach prevents side flows without creating excessive resistance to the main fluid flow path through the filters.
Solution Approach 2:
The frame acts as an intermediary structure between the multiple filter medium bodies and the housing. It provides a sealed interface with the housing while organizing the filter stages, creating controlled flow paths that prevent side flows without significantly increasing pressure drop across the entire filter element.
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 configuration improves adsorption capacity, dust capacity, and separation efficiency while reducing pressure drop, effectively filtering particles and harmful gases from intake air, and optimizing the use of available installation space.
Implementation Method 1
a flat-filter filter element for filtering a fluid, in particular for filtering air
Implementation Method 2
Fuel cell systems often require a particle filter and an adsorption filter to filter both particles and harmful gases from the intake air
Data Source
AI summary
The invention relates to a flat-filter filter element for filtering a fluid, in particular for filtering air, for a filter system, in particular for an air filter system of a fuel cell system, having an arrangement of at least two flat-filter medium bodies being arranged adjacent to each other in an axial direction, so that the fluid can flow through them one after the other in the axial direction. The flat-filter filter element comprises an overmolded plastic frame that is directly molded to an outer circumference of one of the filter medium bodies, and the other one of the filter medium bodies is sealingly connected to the overmolded plastic frame by means of a circumferential cast element.