Tapering Filter Support Sections for Zigzag Media
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Solution Overview
Problem
Existing filter elements with zigzag-folded filter media face challenges in maximizing the effective filter area while minimizing material and manufacturing costs, and in maintaining optimal fold shape and loading capacity.
Innovation Solution
The filter element incorporates tapering support sections made of adhesive, with a cross-sectional area that decreases from the fold tip to the fold base, reducing material usage and internal stresses, and featuring a ratio of height to width that optimizes the filter surface area and fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support sections with uniform cross-section are used in filter elements, then manufacturing is simplified, but material usage increases and effective filter area decreases
Solution Approach 1:
The support sections are designed with a tapered cross-section where the width decreases from the fold base to the fold tip. This local variation in geometry allows the support sections to provide maximum support where needed (at the fold base) while minimizing material consumption toward the fold tip, thereby resolving the contradiction between manufacturing simplicity and material efficiency.
2Strength
If support sections with larger cross-section are used, then structural strength is improved, but effective filter surface area is reduced
Solution Approach 1:
The tapered design of support sections concentrates the cross-sectional area at the fold base where structural support is most critical, then gradually reduces the width toward the fold tip. This local quality variation ensures adequate structural strength at key locations while maximizing the effective filter surface area in regions where support is less critical.
3Stability of the object's composition
If support sections extend fully across folds, then fold stability is improved, but free volume in fold gaps is reduced
Solution Approach 1:
The support sections are positioned and dimensioned to provide stability at the fold base where they are needed most, while their tapered geometry allows them to recede toward the fold tip. This creates sufficient free volume in the fold gaps for fluid flow while maintaining fold stability at critical locations.
Data Source
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AI summary
The description relates to a filter, and a filter element of a filter for filtering fluids, particularly gases, particularly intake air, particularly for an internal combustion engine, particularly a motor vehicle. The filter element has a filter medium (16) folded in zigzag form, comprising a raw fluid side (12) and a pure fluid side (14). On the raw fluid side (12) and/or on the pure fluid side (14) of the filter medium (16), at least one elongated support section (44) is arranged on a corresponding surface of the filter medium (16), said support section running obliquely or perpendicular to fold edges (46) of the filter medium (16) at least in sections. A height extension (50) of the at least one support section (44) perpendicular to the surface of the filter medium (16) along the longitudinal direction (52) thereof increases in the direction from a fold base (48) to a fold peak (20) of a fold (18) of the filter medium (16), so that the at least one support section (44) on the folded filter medium (16), the free side (60) thereof facing away from the surface of the filter medium (16), is in contact with a corresponding free side (60) of an opposite support section (44) in a fold intermediate space (62) or with the surface of an opposite medium section in the fold intermediate space. A width extension (54) of the at least one support section (44) parallel to the surface of the filter medium (16) and perpendicular to its longitudinal direction (52) decreases in the direction from the fold peak (20) to the fold base (48) of the fold (18) of the filter medium (16).