Step Filter Airflow Routing for Flexible Vehicle Air Quality

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Solution Overview

Problem

Existing filter devices for motor vehicles lack flexibility in adjusting air quality according to user requirements, often failing to meet predetermined air quality standards in exhaust air streams.

Innovation Solution

A filter device with adjustable air flaps and a step filter comprising individual filter elements arranged in series, allowing two separate air flow paths with different numbers of filter elements, enabling flexible air stream guidance through fine or coarse filter stages, and operation modes for fresh or recirculating air.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple air flaps are used to guide air streams through different filter paths, then air quality flexibility is improved, but device complexity increases

Engineering Contradiction:
Improveair quality flexibilityVSAvoiddevice complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The filter device is segmented into multiple individual filter elements arranged in series, creating distinct filter stages. Each filter element can be independently configured with different filter flap arrangements, allowing the system to provide varied filtering performance across different segments while maintaining overall system flexibility.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The air flaps are designed to be adjustable between different positions, enabling dynamic routing of air streams through different numbers of filter elements. This dynamic capability allows the system to adapt air quality flexibility without requiring completely separate fixed systems for each filtering mode.

Inventive Principle:
Principle #15Dynamics

2Ease of operation

If air flaps are made adjustable in rotatory or translatory manner, then ease of operation is improved, but device complexity increases

Engineering Contradiction:
Improveease of operationVSAvoiddevice complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The air flaps incorporate adjustable mechanisms that enable rotatory or translatory movement between defined positions. These mechanisms are designed to be actuated by actuators that can be controlled based on air quality requirements, providing ease of operation through simple positional changes rather than complex continuous control.

Inventive Principle:
Principle #15Dynamics

3Reliability

If more individual filter elements are arranged in series, then air quality is improved, but loss of time increases

Engineering Contradiction:
Improveair qualityVSAvoidloss of time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system uses adjustable air flaps to dynamically control the number of filter elements through which air streams pass. When high air quality is required, more filter elements are engaged in series. When air quality requirements are lower or rapid response is needed, fewer filter elements are activated, reducing the time delay associated with filtering.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system applies partial filtering action by allowing air streams to pass through a variable number of filter elements based on current air quality demands. This prevents the excessive action of always routing air through the maximum number of filter elements, thereby reducing unnecessary time loss while maintaining adequate air quality when conditions permit.

Inventive Principle:
Principle #16Partial or excessive action

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

Enables flexible adjustment of air quality by guiding air through different filter stages based on air quality demands, maintaining or rapidly achieving desired air quality levels, and reducing the number of required actuators for cost-effective and lightweight design.

Implementation Method 1

air flaps arranged in the filter device, by means of which a first air stream of air of these air streams and/or a second air stream of air of these air streams is guided through or able to be guided through the step filter either along the first flow path or along the second flow path

Methodology Applied
Scientific EffectFluid flow guidance:

Implementation Method 2

step filter of individual filter elements arranged fluidically in series with respect to one another for the stepwise filtering of air

Methodology Applied
Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS12508881B2Filter device of a motor vehicle and method for operating same
Publication Date: 2025.12.30 MAHLE INT GMBH
  • US12508881B2 patent drawing
  • US12508881B2 patent drawing
  • US12508881B2 patent drawing

AI summary

A filter device of a motor vehicle may include a step filter, two flow paths, and a plurality of adjustable air flaps. The step filter may include a plurality of individual filter elements arranged fluidically in series. A first flow path may extend through at least two individual filter elements. A second flow path may extend through a number of the plurality of individual filter elements which, compared to a number of the plurality of individual filter elements through which the first flow path extends, may be reduced by at least one single individual filter element. The plurality of adjustable air flaps may be arranged at least one of upstream and downstream of the step filter. At least one air stream may be guidable through the step filter along at least one of the first flow path and the second flow path via the plurality of adjustable air flaps.