Layered Filter Frame with Channels for Engine Filtration
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Solution Overview
Problem
Filtration systems in internal combustion engines face inefficiencies due to the restriction and dust holding capacity limitations of filter media, which require frequent replacement and can be compromised by the use of adhesive beads that affect filtration efficiency and cross-flow.
Innovation Solution
A filter frame providing structural support and handling features that eliminate the need for adhesive beads by creating boundaries to limit urethane adhesive blowover, increasing usable filter media area, and enhancing cross-flow efficiency, while also facilitating easy servicing with handles that minimize flow disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive beads are used to hold filter media layers together, then structural integrity is improved, but filtration efficiency deteriorates due to adhesive blowover affecting cross-flow
Solution Approach 1:
The patent removes adhesive beads entirely from the filter element design. Instead of using adhesive to bond filter media layers, the invention uses a frame structure with channels that mechanically hold the layers together, eliminating the source of adhesive blowover that compromises filtration efficiency.
Solution Approach 2:
The patent introduces a frame structure with channels as an intermediary mechanism between filter media layers. This frame structure provides the structural integrity previously achieved by adhesive beads, while using a different mechanism (mechanical channel engagement) that does not interfere with filtration efficiency.
2Duration of action of stationary object
If filter media volume is increased to extend dust holding capacity, then service life is improved, but pressure drop increases reducing flow efficiency
Solution Approach 1:
The patent uses a layered construction with multiple thin filter media layers arranged in parallel, rather than a single thick layer. This dimensional approach allows increasing the total filtration surface area and dust holding capacity without proportionally increasing the thickness that would cause pressure drop. The channels provide cross-flow paths that maintain low pressure drop.
Solution Approach 2:
The patent divides the filter media into multiple separate layers held together by the frame structure. This segmentation allows each layer to contribute to dust holding capacity while the channel structure maintains open flow paths, preventing the pressure drop that would result from a single compacted thick filter layer.
3Ease of manufacture
If filter element design is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but handling and installation difficulty increases
Solution Approach 1:
The frame structure serves multiple functions simultaneously: it provides structural integrity to hold filter media layers, creates channels for cross-flow filtration, and forms handles for easy handling and installation. This multi-functionality simplifies the overall design while improving ease of operation.
Solution Approach 2:
The patent combines the structural support function, flow channel function, and handling function into a single integrated frame structure. This merging eliminates the need for separate adhesive beads and separate handling features, simplifying manufacturing while improving ease of installation and removal.
Data Source
AI summary
Various embodiments relate to a filter element. The filter element includes a first filter end, second filter end, filter media, and filter frame. The second filter end is disposed axially away from the first filter end. The filter media extends axially between a first filter end and a second filter end. The filter frame is adjacent to the first filter end. The filter frame includes a first frame end, a second frame end, a first frame endwall, a second frame endwall, a first frame sidewall, and a second frame sidewall. The second frame end is disposed axially away from the first frame end. The first frame endwall extends axially away from the first frame end toward the second frame end. The second frame endwall extends axially away from the first frame end toward the second frame end. The second frame endwall is disposed longitudinally away from the first frame endwall.