Radially Nested Bellows Air Filter for Combustion Engine
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Solution Overview
Problem
Existing air filters for internal combustion engines require complex construction and maintenance, compromising filtration performance and ease of service.
Innovation Solution
A filter device featuring a main filter element designed as a multiple bellows filter with radially nested star-shaped filter bellows, sealed by a TPE double-lip sealing ring, allowing radial and axial fluid flow with efficient separation of clean and dirty gas sides, and featuring a cyclone pre-separator and fine filter for enhanced filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional air filter design with multiple separate components is used, then the filtration performance can be maintained, but the device complexity and maintenance effort increase
Solution Approach 1:
The patent combines multiple filtration stages (pre-separator, main filter element, and fine filter) into a single integrated filter cartridge that can be installed as one unit. The main filter element features radially nested bellows structures with filter folds arranged in multiple stages, merging what would traditionally be separate components into one unified assembly, thereby reducing device complexity while maintaining comprehensive filtration performance
Solution Approach 2:
The filter element employs radially nested bellows structures where inner bellows are positioned within outer bellows. This nesting arrangement allows multiple filtration surfaces to be compactly arranged in a radial configuration, maximizing filtration area within a constrained axial space while simplifying the overall construction by eliminating the need for multiple separate filter housings
2Reliability
If a complex multi-component filter system is implemented, then filtration effectiveness is improved, but the ease of operation and maintenance deteriorates
Solution Approach 1:
The patent integrates the pre-separator, main filter element, and fine filter into a single replaceable cartridge assembly. This merging allows the entire multi-stage filtration system to be installed and maintained as one unit, significantly reducing maintenance effort compared to traditional systems requiring separate handling of multiple components, while preserving comprehensive filtration effectiveness through the multi-stage design
3Device complexity
If axial flow through the filter element is used, then the construction is simplified, but the filtration performance and flow distribution are compromised
Solution Approach 1:
The patent transitions from purely axial flow to a combination of radial and axial flow paths. The filter folds are arranged radially with their end edges extending axially, creating flow chambers that guide fluid radially through the filter material while maintaining axial progression. This radial-axial flow configuration improves filtration performance and flow distribution compared to simple axial flow, while the integrated bellows structure keeps construction relatively simple
4Area of stationary object
If multiple filter bellows are arranged radially, then the filtration area is increased, but the device complexity increases
Solution Approach 1:
The patent arranges multiple filter bellows in a radially nested configuration where inner bellows are positioned within outer bellows. This nesting strategy increases the total filtration area by creating multiple radial flow paths through different bellows, while simultaneously reducing structural complexity by eliminating the need for separate housings for each bellows. The shared cylindrical structure provides support for all nested bellows, achieving both increased filtration area and simplified construction
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 solution provides high filtration performance with simplified construction and easy maintenance, ensuring efficient air filtration for internal combustion engines while minimizing operational effort.
Implementation Method 1
A cyclone pre-separator is installed upstream of the filter cartridge, which is used to separate coarse dirt particles
Implementation Method 2
at least one filter bellows is to flow through in the radial direction and between the filter bellows a flow chamber for the fluid is formed
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a main filter element (22) for a filter device (10), in particular an air filter for an internal combustion engine, which can be arranged in a filter housing (12). A fluid to be filtered flows through this housing. The main filter element (22) is designed as a multi-bellows filter with at least two radially nested filter bellows (32, 34), wherein at least one of the filter bellows (32, 34) is designed for radial flow. A flow chamber (44) for the fluid is formed between the filter bellows (32, 34). This chamber communicates with an end face of the main filter element (22), each of the filter bellows (32, 34) being designed as a star filter with star-shaped filter pleats. A seal (36) for sealing against a filter housing (12, 104) is located on at least one end face of the main filter element (22).