Segmented Filter Bellows for Complex Engine Geometries
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Solution Overview
Problem
Existing filter elements for internal combustion engines in motor vehicles face challenges in flexible installation and efficient use of available space, as they often require complex trimming and assembly from multiple sub-elements to fit various geometries, limiting design freedom and increasing production costs.
Innovation Solution
A filter element with a filter bellows made of a filter medium folded in a zigzag shape, comprising multiple element sections with end edge surfaces that change direction at obtuse angles, allowing for flexible installation and adaptation to complex geometries, with lateral sealing to ensure fluid-tight separation and increased stability through a one-piece production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If filter bellows are made with straight and parallel front edges and fold lines, then manufacturing is simple, but adaptability to complex installation spaces is poor
Solution Approach 1:
The filter bellows is divided into multiple element sections (first, second, and optional third sections) with distinct directional orientations. Each section can be independently configured to match different geometric requirements of installation spaces, eliminating the need for complex trimming and assembly of multiple sub-elements.
Solution Approach 2:
The end-edge surfaces are designed with asymmetric directional changes at obtuse angles rather than symmetric straight parallel edges. This asymmetric configuration allows the filter bellows to adapt to irregular and complex installation spaces while maintaining manufacturing simplicity through continuous folding patterns.
2Volume of moving object
If filter medium is folded in zigzag pattern to fit complex spaces, then space utilization improves, but structural stability decreases
Solution Approach 1:
By segmenting the filter bellows into multiple element sections with defined fold lines and sealed folds, the structure maintains stability through controlled folding patterns. The segmentation allows volume optimization for complex spaces while preserving structural integrity through systematic fold configurations.
Solution Approach 2:
The filter medium is folded into a flexible bellows structure that can conform to complex installation spaces. The folding pattern creates a flexible yet stable configuration that utilizes available space efficiently while maintaining structural composition through the continuous folded form.
3Adaptability or versatility
If multiple sub-elements are assembled to fit various geometries, then adaptability increases, but device complexity and production costs increase
Solution Approach 1:
Multiple functional sections that would traditionally require separate sub-elements are merged into a single continuous filter bellows structure. The first, second, and optional third element sections are formed from continuous filter medium with defined fold lines, eliminating the need for multiple assembly steps while maintaining design freedom for various geometries.
Solution Approach 2:
The filter bellows design with multiple element sections and obtainable directional changes serves multiple geometric configurations universally. A single design can adapt to different installation spaces (flat, bent, triangular, trapezoidal) without requiring separate sub-elements or complex assembly procedures.
4Manufacturing precision
If extensive trimming is performed to fit filter elements, then geometry precision improves, but material waste and production time increase
Solution Approach 1:
The filter bellows is pre-formed with the correct geometry through controlled folding of the filter medium into multiple element sections with specific directional changes. This preliminary formation of the final geometry eliminates the need for extensive post-folding trimming, preserving material and reducing production time while maintaining precision.
Solution Approach 2:
The geometry of the filter bellows is achieved by changing the folding parameters (fold lines, element section directions, obtuse angles) rather than by trimming. This parameter-based formation allows precise geometry control through the folding process itself, minimizing material waste while achieving the required geometric precision for various installation spaces.
Data Source
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AI summary
The invention relates to a filter element (10) for filtering a fluid, in particular of an internal combustion engine, in particular of a motor vehicle, said element having filter bellows (12) made of a filter medium (14) folded into zig-zag-shaped pleats (34) along fold edges (26), each pleat extending between opposing end edges (22a, 22b) of the filter bellows (12), and being laterally sealed at the end edges (22a, 22b) by means of at least one sealant track (42). The filter bellows (12) comprise at least a first element section (16) and a second element section (17), each having end edge surfaces (20a, 20b) and (21a, 21b) running substantially parallel to one another on opposing end faces (18, 19), wherein, from one element section (16, 17) to another element section (17, 16), at least one of the end edge surfaces (20a, 20b) changes direction. The invention also relates to the use of the filter element (10) as a flat air filter, in particular a flat air filter of an internal combustion engine.