Gas Filter Insert With One-Piece Base and Hollow Foot
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Solution Overview
Problem
Existing gas filter inserts for internal combustion engines are complex to produce and prone to air leakage due to multi-part constructions, which can lead to detachment during vibrations or impacts.
Innovation Solution
A U-shaped pleated filter insert with a one-piece plastic filter base body and a hollow fastening foot, where the pleated filter is securely held by a sealing element that covers the end edges and support elements, eliminating the need for direct connection methods like welding or gluing, and ensuring a tight seal without complex sealing measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-part filter body construction is used with welding or gluing, then the pleated filter can be securely attached, but the manufacturing complexity increases and air leakage risks arise during vibrations or impacts
Solution Approach 1:
The filter body is designed as a single-piece molded component that integrates the upper and lower shells into one unified structure. This eliminates the need for separate welding or gluing operations between multiple parts, reducing manufacturing complexity while maintaining secure attachment of the pleated filter through integrated support elements and sealing structures.
Solution Approach 2:
A sealing element is introduced as an intermediary component between the pleated filter and the filter body. This sealing element is molded into the single-piece filter body structure and provides both sealing and mechanical attachment functions, eliminating air leakage paths while avoiding complex multi-step assembly processes.
2Strength
If welding or gluing is used to attach the pleated filter to the filter body, then secure attachment is achieved, but the structure becomes prone to air leakage under vibrations or impacts
Solution Approach 1:
A sealing element in the form of a flexible seal is integrated into the filter body structure. This sealing element conforms to the pleated filter surface and maintains continuous contact under vibrations and impacts, providing reliable air tightness without the brittle failure modes associated with welding or gluing.
Solution Approach 2:
The sealing function and structural support functions are merged into a single integrated sealing element that is molded as part of the filter body. This eliminates the interface between separate sealing components and the filter body, removing potential leakage paths while maintaining attachment strength.
3Ease of manufacture
If a single-piece filter body is used, then manufacturing is simplified and air tightness is improved, but additional sealing measures may be needed to secure the pleated filter
Solution Approach 1:
The sealing element is designed to perform multiple functions simultaneously: it provides air sealing between the pleated filter and filter body, serves as a mechanical attachment element, and distributes clamping forces evenly. This multi-functionality is integrated into the single-piece mold design, eliminating the need for separate sealing measures.
Solution Approach 2:
The sealing element is molded directly into the filter body structure during the single-piece manufacturing process. The geometry of the sealing element and its interaction with the pleated filter create self-retaining features that automatically secure the filter without requiring additional external sealing components or complex assembly steps.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The gas filter insert (1) has a U-shaped folded filter (2), which is received in a filter base body (4). The filter base body is formed as one-piece component with a receiving space, in which the folded filter is inserted. The filter base body has a mounting foot which extends between upper and lower shells (5,6) and is arranged between the brackets of the U-shaped folded filter. The mounting foot is formed as hollow foot (7).