Oval Filter Element with Foam Frame for Compact Engine Spaces
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Solution Overview
Problem
The increasing trend towards compact vehicles in automobile construction has resulted in limited space for filter systems in engine compartments, making it challenging to accommodate standard rectangular filter cartridges, often requiring the arrangement of two filters or systems in different locations.
Innovation Solution
A filter element with an oval contour is designed, featuring a beveled zigzag filter medium surrounded by a polyurethane foam frame with a sealing edge, reinforced with hot-melt glue beads and a thermoplastic support frame, optimizing spatial utilization and ensuring reliable sealing and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard rectangular filter cartridge is used, then the filter structure is simple and easy to manufacture, but it cannot be accommodated in limited engine compartment spaces
Solution Approach 1:
The filter element is designed with an oval contour instead of a standard rectangular shape. The filter medium is cut and folded to create curved surfaces that conform to the oval geometry, allowing the filter to adapt to limited installation spaces in the engine compartment while maintaining structural integrity
Solution Approach 2:
The filter medium is folded in a zigzag pattern, transforming a two-dimensional flat filter into a three-dimensional oval-shaped filter element. This folding creates multiple layers and dimensions that maximize filtration surface area within the constrained oval housing space
2Volume of moving object
If the filter medium is folded in a zigzag shape to create an oval contour, then spatial utilization is optimized, but the sealing complexity increases
Solution Approach 1:
A polyurethane foam frame is introduced as an intermediary sealing element between the folded filter medium and the oval housing. This frame provides a simplified sealing solution that accommodates the zigzag-folded filter medium while ensuring a reliable seal without complex sealing mechanisms
Solution Approach 2:
The polyurethane foam frame acts as a flexible sealing shell that conforms to the oval contour and accommodates the folded filter medium. This flexible frame provides a simple yet effective sealing solution that handles the complexity of the zigzag fold without requiring complex rigid sealing structures
3Reliability
If adhesive beads are applied continuously during production, then lateral sealing is achieved, but production time and material consumption increase
Solution Approach 1:
The sealing function is extracted from the continuous adhesive application process and transferred to the polyurethane foam frame structure. The frame itself provides the lateral sealing, eliminating the need for continuous adhesive beads and improving production efficiency while maintaining seal reliability
Solution Approach 2:
The polyurethane foam frame serves as a disposable sealing element that is applied in its complete form rather than requiring continuous adhesive application during production. This approach reduces production time and material consumption while ensuring reliable lateral sealing
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 oval filter element effectively adapts to limited spaces, providing a reliable seal and easy handling, allowing for efficient air filtration with minimal filter medium waste and reduced installation complexity.
Implementation Method 1
The transition from the filter medium to the corresponding opening, which is to be filled with the filter element, takes place through a polyurethane foam frame, which is provided with a sealing edge
Implementation Method 2
These reinforcement strips are, for example, beads of glue made of hot-melt glue or another stabilizing material
Data Source
Figure 1
Figure 2
AI summary
A filter element consists of a zig-zag folded filter medium (11) in plate form, enclosed in an oval peripheral frame (12) of polyurethane foam. The filter medium has slanting side regions reproducing the oval contour, so that a maximum possible filtration surface is obtained with minimal cutting. The opening of the frame has a peripheral groove (13) or flange to provide a seal.