Integrated Center Pipe for Dual-Stage Air Filter Assembly
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Solution Overview
Problem
Existing air filter systems for internal combustion engines face challenges in efficiently managing the replacement and recycling of primary and secondary filter elements, leading to increased manufacturing and recycling costs, as well as potential contamination during maintenance.
Innovation Solution
A filter system design that integrates a primary and secondary filter element with a combined center pipe, allowing for reproducible positioning and easy replacement, reducing waste and tooling costs, and ensuring effective sealing and interchangeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate primary and secondary center pipes are used, then the filter elements can be independently replaced, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the primary center pipe and secondary center pipe into a single integrated center pipe structure. The primary filter element is mounted on the outer surface of the integrated center pipe, while the secondary filter element is mounted inside the integrated center pipe. This merging eliminates the need for separate center pipes, reducing device complexity and manufacturing costs while maintaining the capability for independent filter element replacement.
Solution Approach 2:
The patent implements a nested arrangement where the secondary center pipe is positioned inside the primary center pipe, forming a concentric structure. The secondary filter element is mounted on the inner secondary center pipe, while the primary filter element is mounted on the outer primary center pipe. This nesting allows both filter elements to be independently accessed and replaced without requiring separate external center pipes.
2Ease of repair
If traditional separate center pipes are used, then filter elements can be replaced, but recycling costs and waste increase
Solution Approach 1:
The integrated center pipe design allows the center pipe structure itself to be recovered and reused when filter elements are replaced. Since the center pipe is a single integrated piece that houses both filter elements, it can be retained in the housing while only the filter elements are removed and replaced. This eliminates the waste of discarded center pipes and reduces recycling costs, as the center pipe structure does not need to be discarded with the filter elements.
3Ease of operation
If separate center pipes are used, then filter elements can be independently maintained, but tooling and manufacturing costs increase
Solution Approach 1:
The patent merges the primary and secondary center pipes into a single integrated center pipe component. This reduces the number of parts that need to be manufactured, assembled, and inventoried. The integrated center pipe can be produced as a single piece or pre-assembled unit, simplifying manufacturing processes and reducing tooling costs compared to producing and assembling separate center pipes.
4Ease of operation
If the secondary filter element is positioned without defined rotational positioning, then assembly is simpler, but the reproducibility of assembly conditions deteriorates
Solution Approach 1:
The patent employs asymmetric positioning features on the secondary center pipe, such as positioning protrusions or keyed structures, that engage with corresponding features on the secondary filter element. This asymmetric design defines a specific rotational position for the secondary filter element, ensuring reproducible assembly conditions while maintaining relatively simple assembly procedures. The asymmetric features guide the filter element into the correct orientation during installation.
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 integrated filter system reduces manufacturing and recycling costs, minimizes waste, and ensures safe and economical maintenance by allowing for reproducible assembly and interchangeability of filter elements, while maintaining effective air filtration.
Implementation Method 1
The secondary filter element itself also has a filter medium which keeps residual dirt particles away from the filter outlet in the air stream
Data Source
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AI summary
The invention relates to a filter system (100) comprising a housing (110), a fluid inlet (102) formed in a first housing part (112), a fluid outlet (108) formed in the first housing part (112), a primary filter element (50) and a secondary filter element (10), both being accommodated in the housing (110), wherein an integrated center pipe (60) is arranged inside the housing (110), the integrated center pipe (60) comprising a primary center pipe (62) and a secondary center pipe (150) being arranged inside the primary center pipe (62), the primary center pipe (62) and the secondary center pipe (150) being attached to each other at a first axial end (70) of the integrated center pipe (60), wherein the first axial end (70) is directed to the fluid outlet (108), wherein the first axial end (70) of the integrated center pipe (150) is attached to the first housing part (112).