Super-pleated Vehicle Air Filter with Wire Support
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Solution Overview
Problem
Conventional air filters for internal combustion engines are inadequate in effectively removing particulate matter and contaminants from the airstream, leading to mechanical wear and oil contamination, and often require frequent replacement rather than cleaning.
Innovation Solution
An air filter system with a thicker filter medium, potentially incorporating a wire support and pleated or contoured design, is mounted onto the air inlet of an internal combustion engine, using end caps made of deformable materials to securely attach to existing bases and covers, allowing for easy installation and periodic cleaning without altering the base or cover, and utilizing materials like paper, foam, cotton, or fiberglass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air filters are used, then the filter structure is simple, but the filtration effectiveness is insufficient and mechanical wear occurs
Solution Approach 1:
The patent applies composite materials by combining a pleated filter element with a wire support structure. The filter element consists of multiple layers including a pleated paper or foam filter medium, a wire support mesh, and potentially an oil-coating layer. This composite structure enhances filtration effectiveness while maintaining reasonable structural complexity through integrated design of the support and filtering functions.
Solution Approach 2:
The filter element is segmented into distinct functional layers: a pleated filter medium for particle capture, a wire support mesh for structural integrity, and an oil-coating layer for enhanced filtration. This segmentation allows each layer to perform its specific function optimally while working together as an integrated system.
2Duration of action of stationary object
If conventional air filters are used, then the filter is easy to install, but it requires frequent replacement rather than cleaning
Solution Approach 1:
The patent enables recovery and reuse of the filter by designing it with removable components. The pleated filter element can be detached from the housing, cleaned of accumulated particulate matter, and reused. The wire support structure remains in place while the filter medium can be cleaned and reused multiple times, reducing the need for frequent replacement.
Solution Approach 2:
The patent changes the operational parameters of the filter by introducing an oil-coating layer that can be cleaned and reused. The oil coating enhances filtration capabilities and can be maintained through periodic cleaning, allowing the filter to extend its service life beyond conventional disposable filters.
3Reliability
If a thicker filter medium is used, then filtration capabilities are enhanced, but the filter becomes more complex
Solution Approach 1:
The thicker filter medium is segmented into functional layers including a pleated paper or foam filter medium, a wire support mesh, and an oil-coating layer. This segmentation allows the thickness to be distributed across multiple functional elements rather than a single dense medium, enhancing filtration capabilities while maintaining structural manageability.
Solution Approach 2:
The patent adds a dimensional aspect by pleating the filter medium, which increases the effective filtration surface area within the available space. The pleats create multiple folds that extend the filtration path length, enhancing capabilities without proportionally increasing overall filter thickness or complexity.
4Strength
If wire support is incorporated, then durability is increased, but manufacturing complexity increases
Solution Approach 1:
The patent merges the wire support function with the filter element assembly by integrating the wire mesh directly into the pleated filter structure. The wire support is combined with the filter medium in a unified assembly that can be manufactured as a single unit or pre-assembled components, reducing the number of separate parts and simplifying manufacturing.
Solution Approach 2:
The wire support structure serves multiple functions: it provides structural durability to prevent filter collapse, maintains the pleated configuration during operation, and acts as a reinforcement framework. This multi-functionality reduces the need for additional separate components, thereby reducing manufacturing complexity.
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 air filter system provides enhanced filtration capabilities, increased durability, and the option for reuse by incorporating a wire support and oil-enhanced cleaning properties, reducing mechanical wear and extending the filter's lifespan.
Implementation Method 1
A filter medium of the air filter configured to remove particulate matter and other contaminates from an incoming airstream
Implementation Method 2
utilizing materials like paper, foam, cotton, or fiberglass
Data Source
AI summary
An apparatus and method are provided for an air filter configured to be mounted onto an air inlet of an internal combustion engine. The air filter comprises a first end cap configured to couple with a base which is configured to support a conventional air filter and provide an interface between the conventional air filter and the air inlet. A filter medium which is relatively thicker than the conventional air filter is configured to remove particulate matter and other contaminates from an incoming airstream. A second end cap is configured to couple with a cover which is configured to fasten the conventional air filter and the base onto the air inlet, such that the incoming airstream is directed through the filter medium. The air filter is configured to be installed in place of the conventional air filter without necessitating alteration of the base and cover.