Heated Air Filter Wave Bending Short Circuit Prevention
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Solution Overview
Problem
Existing electrically heated air filters for helicopter intake systems face challenges in manufacturing precision to avoid short circuits between collectors, and are complex and costly to produce.
Innovation Solution
The design features a pleated air filter with a peripheral frame supporting a filtering material panel enclosed between thin, pleated outer and inner reinforcement meshes, with electrified warp wires in the outer mesh generating heat through the Joule effect, and collectors arranged to prevent short circuits using insulating support elements and coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the unit consisting of the filtering material panel enclosed between the outer reinforcement mesh and the inner reinforcement mesh is bent in waves, then the air filter can be equipped with an electric heater device, but the manufacturing precision requirement increases to avoid short circuits between collectors
Solution Approach 1:
The patent applies preliminary action by pre-forming the wave shape of the reinforcement meshes and positioning the collectors before the bending operation. The collectors are预先 placed on the outer reinforcement mesh at the correct positions, and the wave bending is then performed in a controlled manner to avoid displacing the collectors and causing short circuits.
Solution Approach 2:
The patent introduces an intermediary element (support structure or template) during the bending process to maintain the correct spacing and positioning of the collectors. This intermediary tool ensures that the wave bending does not cause adjacent collectors to come into contact, thereby preventing short circuits while achieving the desired wave shape.
2Reliability
If the unit is bent in waves to accommodate the heater device, then the electric current can flow through the outer reinforcement mesh, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent merges the structural reinforcement function with the electrical heating function by integrating the collectors directly into the outer reinforcement mesh structure. The collectors are welded to the warp wires of the mesh, combining the mechanical support role of the reinforcement mesh with the electrical conduction role of the heater device, thereby reducing the number of separate components and simplifying manufacturing.
Solution Approach 2:
The outer reinforcement mesh serves multiple functions: it provides structural support to the filtering material panel, acts as a conductor for the electric heater device, and maintains the positioning of the collectors. This multi-functionality reduces the overall complexity of the device by eliminating the need for separate structural and electrical components.
3Power
If collectors are positioned close together to maximize heating coverage, then the heating efficiency improves, but the risk of short circuits between adjacent collectors increases
Solution Approach 1:
The patent applies local quality by providing enhanced electrical insulation specifically at the locations where collectors are positioned close together. Insulating materials or coatings are applied locally at the collector positions and in the gaps between adjacent collectors, allowing for close spacing to maximize heating coverage while maintaining reliable electrical insulation to prevent short circuits.
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 reduces the risk of short circuits, simplifies manufacturing, and results in an efficient, cost-effective electrically heated air filter that can operate in cold conditions, maintaining airflow and mechanical strength while minimizing electrical resistance and heat generation costs.
Implementation Method 1
designed to make an electric current flow through the electrified wires to generate, due to the Joule effect, heat inside the outer reinforcement mesh
Data Source
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AI summary
An electrically heated air filter (9) for an intake system (8) of an engine (2) of a vehicle (1); the air filter (9) has: an outer reinforcement mesh (12); an inner reinforcement mesh (13); a filtering material panel (11), which is enclosed between the outer reinforcement mesh (12) and the inner reinforcement mesh (13) and is bent in waves; two successions of collectors (19), which are arranged at opposite ends of the outer reinforcement mesh (12) and determine an electrical connection, which is partly in parallel and partly in series, of the warp wires (14) or of the weft wires (15) of the outer reinforcement mesh (12); and a heating device (17), which, also using the collectors (19), is designed to cause an electric current (I) to flow through part of the outer reinforcement mesh (12). In each succession of collectors (19), the collectors (19) alternatively rest against a first portion (23) of a surface of the respective wires (14; 15) of the outer reinforcement mesh (12) oriented in a direction away from the filtering material panel (11) and against a second portion (24) of the surface of the respective wires (14; 15) of the outer reinforcement mesh (12) oriented towards the filtering material panel (11).