Folded Filter Media Structure for Cross-Flow in Tight Spaces
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Solution Overview
Problem
Existing filter assemblies struggle to accommodate complex shapes and maintain structural integrity in space-constrained environments, leading to issues such as undesirable media contact and increased pressure drop, while also requiring efficient particulate removal from fluid streams in internal combustion engines.
Innovation Solution
The development of filter elements with a filter media layer folded along bend lines, featuring serpentine wall segments and tetrahedral arrangements, which allow for complex shapes and enhanced cross-flow filtration, supported by internal and external ribs to maintain structure and minimize pocket movement during high pressure applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the filter media is folded along multiple bend lines to create complex shapes, then the filter element can accommodate space-constrained mounting structures, but the structural integrity and stability of the filter element deteriorates
Solution Approach 1:
The filter media is divided into multiple panels separated by bend lines, creating a modular structure that can be folded into complex shapes while maintaining the integrity of each individual panel. The segmentation allows the filter element to adapt to mounting structures with varying curvature and orientation.
Solution Approach 2:
Ribs are extracted as separate structural elements from the filter media and integrated at strategic locations to provide additional support. These ribs are taken out as distinct features that reinforce the folded structure without interfering with the filtration function of the media.
2Volume of moving object
If the filter media is folded along bend lines to create complex shapes, then the filter element can fit in constrained spaces, but undesirable media contact occurs between adjacent panels
Solution Approach 1:
Ribs serve as intermediary elements positioned between adjacent filter media panels. These ribs act as spacers that prevent direct contact between the media surfaces, eliminating the harmful effect of media-to-media contact while maintaining the compact folded structure.
3Ease of manufacture
If the filter element structure is simplified to reduce manufacturing complexity, then the ease of manufacture improves, but the ability to accommodate complex mounting structures deteriorates
Solution Approach 1:
The filter media itself is utilized as a flexible structural component that can be folded along predetermined bend lines. This approach eliminates the need for rigid support frames or complex mounting hardware, allowing the media to conform to various mounting structures while maintaining manufacturing simplicity.
4Stability of the object's composition
If ribs are added to maintain structural integrity, then the stability of the filter element improves, but the device complexity increases
Solution Approach 1:
The ribs are merged with the filter media panels at their boundaries, combining the structural support function with the existing panel architecture. This integration approach adds necessary stability while minimizing the increase in overall device complexity by reusing existing structural elements.
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 design enables efficient filtration with reduced initial pressure drop and increased dust loading capacity, while accommodating complex mounting structures, thereby enhancing filtration efficiency and durability in constrained spaces.
Implementation Method 1
a filter element structured to remove the particulate matter from the fluid prior to delivering the fluid
Implementation Method 2
The second subset of bend lines provide lateral cross-flow thereacross along the lateral direction between axial channels downstream of the upstream inlet
Data Source
AI summary
Embodiments described herein relate generally to filter assemblies that include filter elements with cross-channel flow having flat and/or folded arrangements for optimized functionality and performance. The filter assemblies may be formed (e.g., shaped, constructed, etc.) using a variety of shapes, angles, configurations, and materials to improve the filtration and cross-channel flow of fluid through the filter media. The filter media may implement a wide variety of patterns (e.g., repeating, origami, rounded, etc.), shapes (e.g., tetrahedral, rhombus, square), and construction (e.g., pleated, integrated, interdigitated, etc.).