Multilayer Wrapped Filter Elements for Complex Sealing Geometry

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Solution Overview

Problem

Existing filter assemblies face challenges in accommodating complex shapes due to space constraints and unique mounting structures, requiring innovative filter element designs that can efficiently filter particulate matter while maintaining sealing and reducing pressure drop.

Innovation Solution

The development of multilayered filter elements with a polymeric layer on the sidewalls of the filter media pack, featuring indentations and non-circular cross-sections, allows for complex shapes that fit within constrained spaces and provides integrated sealing, reducing manufacturing costs and pressure drop.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional filter elements are used, then manufacturing is simpler, but they cannot accommodate complex mounting structures and space constraints

Engineering Contradiction:

Improveadaptability to complex mounting structuresVSAvoidfilter element shape complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The filter element is divided into multiple filter media layers stacked on top of each other, allowing the filter to achieve complex three-dimensional shapes while maintaining manufacturability. Each layer can be independently formed and then stacked to create the final complex geometry that adapts to various mounting structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple filter media layers are nested stacked on top of each other to form a compact multilayered structure. This nesting approach allows complex shapes to be achieved through layering simpler individual layers, reducing the overall complexity of manufacturing each single complex layer.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If complex filter element shapes are designed to fit constrained spaces, then adaptability improves, but sealing becomes more difficult

Engineering Contradiction:

Improvefit to constrained spacesVSAvoidsealing performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The filter element uses composite construction with multiple filter media layers stacked together, forming a multilayered pack that can be bonded to create integrated sealing surfaces. This composite structure allows the filter to conform to complex mounting structures while maintaining reliable sealing through the bonded interfaces between layers.

Inventive Principle:

Principle #40Composite materials

3Productivity

If traditional single-layer filter media is used, then manufacturing is easier, but filtration efficiency and pressure drop are compromised

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidmultilayered structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The filtration function is segmented across multiple filter media layers, with each layer contributing to the overall filtration efficiency. This segmentation allows the system to achieve high filtration performance while managing pressure drop across multiple stages, and each layer can be manufactured separately using simpler processes before being stacked.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filter design transitions from a single-layer two-dimensional structure to a multilayered three-dimensional pack. By stacking multiple layers in the vertical dimension, the filter achieves enhanced filtration efficiency and controlled pressure drop characteristics that cannot be obtained with a single layer, while each individual layer remains relatively simple to manufacture.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 enables efficient filtration in complex mounting structures with improved sealing and reduced pressure drop, while allowing for flexible installation and cost-effective manufacturing.

Implementation Method 1

a filter element structured to remove the particulate matter from the fluid prior to delivering the fluid

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 2

a polymeric layer disposed on sidewalls of a filter media pack of the filter element

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12515162B2Filter assemblies and elements utilizing multilayered and wrapped filter media

Publication Date: 2026.01.06 ATMUS FILTRATION IP INC

AI summary

A filter assembly comprises a filter element and an outlet flange. The filter element comprises a filter media pack comprising a plurality of filter media layers stacked on top of each other to form the filter media pack. The filter media pack has an inlet surface being at an inlet portion of the filter media pack, and an outlet surface being at an outlet portion of the filter media pack. An outlet flange is coupled to the outlet portion of the filter media pack.