Nested Bellows Air Filter with Deeper Inner Folds

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Solution Overview

Problem

Existing air filter systems for internal combustion engines face challenges in achieving high efficiency and compact design, particularly in environments with varying dust particle sizes, requiring an optimized configuration to ensure reliable filtration and efficient airflow.

Innovation Solution

A multiple bellows filter element design with radially nested filter bellows, where the inner bellows has deeper folds than the outer bellows, and slanted folds to increase the effective filtering surface area, ensuring uniform airflow and compactness, while maintaining shape stability through a shape-preserving shell and sealing configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a folded bellows filter is used to increase filter surface area, then filtering capacity is improved, but device complexity increases

Engineering Contradiction:

Improvefiltering capacityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements nesting by placing a second filter bellows inside the first filter bellows, with the second bellows having a smaller outer diameter than the inner diameter of the first bellows. This nested configuration allows multiple filter surfaces to occupy the same spatial envelope, increasing total filtering capacity without proportionally increasing the overall device size or complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent transitions from a single-layer filter structure to a multi-layer nested structure by adding the second bellows inside the first. This dimensional reorganization allows the filter surface area to expand in the radial direction while maintaining a compact axial profile, effectively utilizing three-dimensional space to increase filtering capacity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If filter folds extend in radial direction to increase surface area, then filtering capacity is improved, but airflow uniformity deteriorates

Engineering Contradiction:

Improvefiltering capacityVSAvoidairflow uniformity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies local quality by giving the inner and outer bellows different fold depths - the second (inner) bellows has deeper folds than the first (outer) bellows. This differential design compensates for the smaller circumference of the inner bellows, ensuring that both bellows provide comparable filtering capacity and maintain uniform airflow distribution across the entire filter element.

Inventive Principle:

Principle #3Local quality

3Productivity

If multiple filter bellows are nested radially to increase efficiency, then filtering capacity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefiltering capacityVSAvoidease of manufacture

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent segments the filter element into distinct modular components - a first filter bellows and a second filter bellows that can be manufactured separately and then assembled together. This segmentation allows each bellows to be produced using standard manufacturing processes, and the final assembly involves simply nesting one bellows inside the other, thereby managing manufacturing complexity while achieving enhanced filtering capacity.

Inventive Principle:

Principle #1Segmentation

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 enhances filtration efficiency and airflow uniformity, allowing for a more compact and effective air filter system that can handle diverse dust particle sizes, improving the overall performance and service life of internal combustion engines.

Implementation Method 1

a filter element (1) for an air filter of an internal combustion engine comprises a first filter bellows (10) with filter folds (15) and a second filter bellows (20) with filter folds (25), wherein the second filter bellows (20) is arranged radially inwardly relative to the first filter bellows (10) and a depth of the second filter folds (25) is deeper than a depth of the corresponding first filter folds (15)

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

slanted folds to increase the effective filtering surface area

Methodology Applied

Scientific EffectGeometric expansion: Geometry

Implementation Method 3

maintaining shape stability through a shape-preserving shell

Methodology Applied

Scientific EffectStructural support:

Implementation Method 4

sealing configuration

Methodology Applied

Scientific EffectSealing:

Data Source

PatentUS8979964B2Efficiency-improved multiple bellows filter

Publication Date: 2015.03.17 MANN HUMMEL GMBH

AI summary

Filter element or air filter in the configuration of a multiple bellows filter with an increased efficiency for use in internal combustion engines, wherein a folded filter bellows is arranged radially inwardly of another folded filter bellows and the inner folded filter bellows has a greater or deeper fold depth than the outer folded filter bellows.