Polyurethane Foam Filter Element Sealing for Vibration Resistance
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Solution Overview
Problem
Existing air filter systems for internal combustion engines face challenges in achieving reliable and temperature-resistant sealing, especially under vibration and shock conditions, while avoiding metallic elements to ensure safe thermal disposal, and maintaining high filtration efficiency.
Innovation Solution
The filter element design incorporates two annular bead-shaped arrangements with a sealing groove, using polyurethane end plates and reinforcement plates with openings for an intimate connection, along with a secondary element for maintaining the filter system's closure during replacement, and employs a cyclone or rotary flow separator for enhanced dirt collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing materials (metal or hard plastic) are used in the filter element, then the sealing reliability under vibration and shock is improved, but the thermal disposal safety is compromised due to metallic elements
Solution Approach 1:
The patent changes the material parameters by using polyurethane foam instead of traditional metal or hard plastic sealing materials. This foam material provides sufficient sealing reliability under vibration and shock conditions while being thermally safe for disposal, thus resolving the contradiction between sealing reliability and thermal disposal safety
Solution Approach 2:
The patent employs a composite structure where a polyurethane foam sealing element is combined with a reinforcement plate. This composite design maintains the soft, thermally-safe sealing properties of the foam while adding structural support to ensure sealing effectiveness under extreme conditions
2Object-affected harmful factors
If soft elastomer materials are used for sealing elements, then the thermal disposal safety is improved, but the sealing effectiveness under extreme temperature fluctuations and vibrations deteriorates
Solution Approach 1:
The patent combines soft polyurethane foam sealing material with a rigid reinforcement plate to create a composite sealing element. The foam provides thermal safety and basic sealing, while the reinforcement plate maintains structural integrity and sealing effectiveness under extreme temperature fluctuations and vibrations
Solution Approach 2:
The sealing element has different local properties: the polyurethane foam portion provides soft, thermally-safe sealing contact, while the integrated reinforcement plate provides rigid structural support. This local differentiation of material properties resolves the contradiction between softness for thermal safety and rigidity for sealing effectiveness
3Ease of manufacture
If the filter element is designed with simple sealing structure, then the ease of manufacture is improved, but the sealing reliability under vibration and temperature fluctuations deteriorates
Solution Approach 1:
The patent integrates the sealing function and reinforcement function into a single composite polyurethane foam element with an embedded reinforcement plate. This integrated design maintains relative manufacturing simplicity while achieving high sealing reliability under vibration and temperature fluctuations
Solution Approach 2:
The patent merges the sealing element and reinforcement structure into a single integrated component. The polyurethane foam sealing element includes an integrated reinforcement plate, eliminating the need for separate assembly steps and simplifying manufacturing while ensuring reliable sealing performance
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 ensures a high sealing effect, supports the filter element securely, and maintains filtration efficiency even under extreme temperature fluctuations and vibrations, allowing for easy replacement without compromising thermal disposal safety.
Implementation Method 1
a cyclone or a rotary flow separator is arranged on the housing in the area of the inlet. This consists of guide geometry that causes the medium to be filtered to rotate. This rotation concentrates the dirt in the area of the housing wall and discharges it at a suitable point
Implementation Method 2
The end caps can also be manufactured using the thixotropic application process. This means that the thixotropic material is metered in while the sealing structure is formed at the same time without additional mold shells
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The invention relates to a filter element consisting of a zigzag-folded filter medium (10) arranged in a concentric shape. End discs (11, 12) are located at the end faces of the medium. The end disc (12) has a concentric opening and comprises a first annular bead (14) and a second annular bead (15), as well as a sealing groove (16) arranged between them. A reinforcing plate (17) is arranged in the area between the filter medium and the annular bead(s) (14, 15). The end faces (18, 19) of the annular bead(s) (14, 16) bear against radially extending ribs (20, 21) of a filter element housing.