Modular Filter Media Arrangement for Custom Packaging
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Solution Overview
Problem
Existing filter element designs for internal combustion engine systems face challenges in customizing shape to fit non-circular or non-rectangular packaging spaces, leading to wasted space and reduced performance, and there is a need to prevent the use of non-genuine filter elements that may be of lesser quality.
Innovation Solution
The use of multiple individual media modules arranged to form a media pack with customizable geometry, including tetrahedral media geometry, which allows for cross-flow and increased filter capacity, and a keyway feature to facilitate alignment and prevent non-genuine element use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional filter element designs are used, then manufacturing is simpler, but they cannot be customized to fit non-circular or non-rectangular packaging spaces, leading to wasted space and reduced performance
Solution Approach 1:
The filter element is divided into multiple individual media modules (e.g., four tetrahedral modules) that can be independently arranged and configured. Each module can be customized in shape and size, allowing the overall filter element to adapt to various packaging space geometries while maintaining manufacturing simplicity through modular assembly
2Productivity
If filter elements are customized to fit packaging spaces, then space utilization and filter capacity increase, but it becomes easier for non-genuine elements to be created and used
Solution Approach 1:
The filter element incorporates asymmetric geometric features including a keyway with specific dimensions and orientation, non-circular cross-sectional shapes, and asymmetric media module arrangements. These unique asymmetric characteristics serve as authentication markers that prevent counterfeit elements from being easily replicated, while the customized geometry simultaneously optimizes space utilization and filter capacity
3Quantity of substance
If media volume is increased to improve filter capacity, then filtration performance improves, but the filter element becomes more complex and difficult to manufacture
Solution Approach 1:
The filter element is segmented into multiple identical or similar media modules (e.g., four tetrahedral modules), each containing a portion of the total media volume. This segmentation allows the total media volume to be increased by simply adding more modules or increasing module size, while maintaining ease of manufacture through standardized, repeatable module production and assembly
Solution Approach 2:
The tetrahedral media modules are arranged in a nested or interlocking configuration that maximizes media volume within the filter element's external dimensions. The geometric nesting allows efficient space utilization without requiring complex internal structures, maintaining manufacturing simplicity while achieving high media volume
Data Source
AI summary
A filter element includes a frame and a media pack coupled to the frame. The frame includes a base, a plurality of receptacles extending across the base, and a keyway disposed in between two receptacles of the plurality of receptacles. The key way is structured to facilitate alignment between the filter element and a filter housing. The media pack includes a plurality of media modules each coupled to a respective one of the plurality of receptacles.