Shaped Air Filter Media Packs for Tight Under-Hood Packaging
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Solution Overview
Problem
Air intake systems face challenges in fitting compact, uniquely shaped air filter assemblies within limited under-hood spaces without sacrificing cost or performance, as conventional filter elements struggle to adapt to reduced space and unusual vehicle shapes.
Innovation Solution
A method of manufacturing a media assembly by winding filter media around a center axis into a media roll and cutting it along specific lines to form flexible, uniquely shaped media packs with sealed sides, allowing for various configurations to fit within diverse spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional filter elements with round, obround, or rectangular flow faces are used, then manufacturing is simple and cost-effective, but the filter assembly cannot fit into limited and unusually-shaped under-hood spaces
Solution Approach 1:
The filter media is divided into multiple pleated panels that can be independently formed and assembled. Each panel can be shaped to fit specific spatial constraints, allowing the overall filter assembly to adapt to unusually-shaped under-hood spaces while maintaining manufacturing efficiency through standardized panel construction methods
Solution Approach 2:
The invention transitions from conventional two-dimensional flat or simple curved filter surfaces to three-dimensionally pleated panels with complex folded geometries. This dimensional complexity allows the filter to conform to irregular under-hood spaces while maintaining adequate filtration surface area within limited package volume
2Volume of moving object
If the filter assembly is made small and unusually shaped to fit limited space, then package volume is reduced, but the available space for filter element within the housing becomes relatively small and unusually-shaped
Solution Approach 1:
The pleated panels are pre-formed with precise geometries before assembly into the final filter housing. This preliminary shaping allows complex three-dimensional configurations to be achieved with high precision, ensuring proper fit within unusually-shaped under-hood spaces while maintaining manufacturing efficiency through standardized panel formation processes
3Adaptability or versatility
If traditional pleated cylindrical air cleaners are replaced with filters that better fit around tubes or align with gradually sloping body panels, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The filter is segmented into multiple pleated panels that can be independently manufactured using standardized processes and then assembled into complex three-dimensional configurations. This segmentation allows each panel to be produced with consistent quality using conventional equipment, while the overall assembly achieves the adaptability needed to fit around tubes and align with sloping body panels
Solution Approach 2:
The pleated panel construction method serves multiple functions: it provides the necessary shape flexibility to adapt to various under-hood spaces, maintains manufacturing efficiency through standardized panel formation, and allows for scalable production. This universal approach replaces the need for completely custom-formed filters for each application
Data Source
AI summary
A method of manufacturing a media assembly comprises winding a filter media about a center axis into a media roll and cutting the media roll along at least two cut lines and into at least two media packs of at least two media assemblies. The media roll is cut along at least one plane that is parallel to the center axis.