Fuel Filter Insert With Gradient-Free Coalescing Layer
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Solution Overview
Problem
Existing fuel filter inserts require high manufacturing costs and large quantities of coalescing medium due to thick, hydrophilic synthetic fiber layers with fiber diameter gradients, resulting in increased space requirements and production complexity.
Innovation Solution
A filter insert with a coalescing medium layer of minimal hydrophilicity and uniform structure/properties, folded into a zigzag shape, having a thickness less than the particle filter medium layer, which acts as a spacer and reduces material usage and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick coalescing medium layer made of hydrophilic synthetic fibers with fiber diameter gradient is used, then water separation efficiency is improved, but manufacturing cost increases and production complexity increases
Solution Approach 1:
The patent changes the hydrophilicity parameter of the coalescing medium layer to a minimum level (isopropanol volume portion of 25% or less in water repellency test), eliminating the need for expensive hydrophilic synthetic fibers with fiber diameter gradients. This parameter change maintains water separation efficiency while dramatically reducing manufacturing cost and production complexity
Solution Approach 2:
The patent applies different properties to different layers: the particle filter medium layer handles particle filtration, while the coalescing medium layer with minimum hydrophilicity handles water coalescence. This local differentiation allows each layer to be optimized for its specific function, reducing overall manufacturing complexity
2Reliability
If a thick coalescing medium layer is used to achieve long dwell time for water droplets, then water separation efficiency is improved, but the quantity of coalescing medium required increases and space requirements increase
Solution Approach 1:
By changing the hydrophilicity parameter to minimum level, the patent achieves effective water coalescence in a thinner layer (0.1-1.5 mm), reducing both the quantity of coalescing medium required and the space needed to house it, while maintaining long enough dwell time for effective separation
Solution Approach 2:
The patent compensates for reduced layer thickness by increasing the surface area through folding the filter material into a zigzag shape, creating a hollow cylindrical or cuboidal body. This dimensional transformation maintains the effective filtration area while reducing the thickness requirement in the flow direction
3Ease of manufacture
If the coalescing medium layer thickness is reduced, then material usage decreases and production complexity decreases, but water separation efficiency may be compromised
Solution Approach 1:
The patent achieves the breakthrough of using a thin coalescing medium layer (0.1-1.5 mm) by changing the hydrophilicity parameter to minimum level, which enables effective water coalescence even in reduced thickness while maintaining separation efficiency
Solution Approach 2:
The zigzag folding configuration compensates for reduced layer thickness by providing extended surface area and longer flow path, ensuring adequate dwell time for water separation despite the thinner coalescing medium layer
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 enables a cost-effective, compact filter insert with a high folding density and effective water separation, maintaining separation efficiency with reduced coalescing medium usage and simpler production processes.
Implementation Method 1
the coalescing medium layer is made of a material having a low hydrophilicity
Implementation Method 2
the coalescing medium layer can act as a spacer between the folds of the particle filter medium layer
Implementation Method 3
the filter material is folded in a zigzag shape to form a hollow cylindrical or cuboidal body
Data Source
AI summary
A filter material for a filter insert of a fuel filter for separating solid particles and water droplets from fuel. The filter material comprises a particle filter medium layer through which the fuel flows first during use and at least one coalescer medium layer which lies on the particle filter medium layer on the outflow side. At least one coalescer medium layer is gradient-free in the flow direction with respect to the geometrical structure and/or physical properties and/or chemical properties of the layers. The at least one coalescer medium layer has a thickness measured in the flow direction which is maximally as large as the thickness of the particle filter medium layer measured in the flow direction.