Spiral Filter Element With Conical Ends For Space Optimization
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Solution Overview
Problem
Existing air filters for internal combustion engines face challenges in maximizing filtration capacity while adapting to limited mounting spaces, as they often have a fixed shape that does not efficiently utilize available space, leading to suboptimal filtration performance.
Innovation Solution
A spirally rolled filter element with alternatingly open and closed flow channels, formed by combining a corrugated and flat filter layer, allows for a tapered shape that optimally fits various mounting spaces, enhancing filtration capacity by creating a larger surface area through strategically positioned adhesive beads to control channel openness at axial ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed cylindrical shape is used for the filter element, then the structure is simple and easy to manufacture, but the filtration capacity is limited due to inefficient space utilization
Solution Approach 1:
The filter element uses a spirally rolled construction with conical end faces instead of a simple cylindrical shape. The spiral rolling creates a curved, tapered structure that better utilizes the available mounting space while maintaining structural integrity and filtration performance.
Solution Approach 2:
The filter element transitions from a two-dimensional cylindrical surface to a three-dimensional spirally rolled structure with conical end faces. This dimensional transformation allows the filter to expand in multiple directions, maximizing space utilization and filtration capacity within the same mounting envelope.
2Productivity
If flow channels are continuously open in axial direction, then the fluid flow resistance is low, but the filtration capacity is reduced as fluid does not pass through the filter medium
Solution Approach 1:
The flow channels are segmented into alternating open and closed sections along the axial direction. This segmentation forces the fluid to alternate between flowing through open channels and permeating through the filter medium in closed channel sections, ensuring both low resistance and high filtration capacity.
Solution Approach 2:
The flow channels exhibit periodic alternation between open and closed states along the axial direction. This periodic structure creates a rhythm of fluid flow that alternates between direct flow paths and filtration paths, optimizing both flow resistance and filtration capacity throughout the filter element.
3Adaptability or versatility
If the filter element is designed with uniform axial length, then the manufacturing is simplified, but the adaptation to various mounting spaces is limited
Solution Approach 1:
The filter element employs asymmetric conical end faces with different semi-vertical angles instead of uniform cylindrical ends. This asymmetric design allows the filter to adapt to various mounting space geometries while the spirally rolled construction maintains manufacturing simplicity through a single continuous rolling process.
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 solution provides improved filtration capacity by maximizing the use of available space, ensuring that no flow channel is continuously open axially, forcing fluid to permeate radially through walls and into neighboring channels for axial discharge, thereby enhancing purification efficiency.
Implementation Method 1
a corrugated filter layer is used onto which a flat filter layer is glued wherein as a result of the corrugations flow channels are formed
Implementation Method 2
the filter element with a spirally rolled filter sheet that has parallel extending flow channels for the fluid to be purified
Implementation Method 3
Closure of the flow channels at the axial end faces is realized by means of an adhesive bead
Implementation Method 4
Filter device for filtration of gaseous fluids
Data Source
AI summary
A filter device for filtering gaseous fluids has a spiral-shaped wound filter path having parallel flow channels for the fluid. The flow channels end in a wound state at an axial face of the filter element at axially different positions. At the second, opposite axial face, the filter element has a geometry deviating from that of the first face.