Two-Bellows Filter Element With Fusion-Sealed, Load-Resistant Interface
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Solution Overview
Problem
Existing multi-stage filter elements for air filtration systems, such as those used in vehicle cabins and fuel cell intake systems, face issues with complex configurations, high material input, high manufacturing costs, and disposal challenges, along with insufficient mechanical load resistance due to connections between filter bellows that are not adequately robust, especially under operational vibrations.
Innovation Solution
A filter element design featuring two filter bellows arranged in series with a circumferentially extending seal directly connected by material fusion, where one bellow has a smaller extension than the other, creating a free space for the seal to attach, enhancing mechanical load resistance and stiffness, and using thermally recyclable materials to address disposal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple filter bellows are connected using a common seal and frame structure, then multi-stage filtration is achieved, but the mechanical load resistance and connection robustness deteriorate
Solution Approach 1:
The patent merges the connection function into the filter bellows themselves by creating a common interface region where multiple bellows adjoin directly. This eliminates separate connection components and creates a unified structure where the bellows support each other mechanically, improving load resistance while maintaining multi-stage filtration.
Solution Approach 2:
The patent segments the filter element into multiple filter bellows that can be flowed through in series, with each bellow containing filter media for different filtration stages. This segmentation allows independent optimization of each bellow's mechanical properties while achieving comprehensive filtration through their combined arrangement.
2Reliability
If separate filter bellows are used for different filtration stages, then filtration effectiveness is improved, but device complexity and material input increase
Solution Approach 1:
The patent combines multiple filter bellows into a single integrated filter element unit that functions as one cohesive component. The bellows are arranged to adjoin in an interface region, creating a unified structure that simplifies installation and handling while maintaining the benefits of multi-stage filtration through the series arrangement.
Solution Approach 2:
The common interface region serves multiple functions simultaneously: it provides mechanical connection between bellows, enables series flow path, and creates a unified support structure. This multi-functionality reduces the need for separate connection components and simplifies the overall device configuration.
3Reliability
If filter bellows are connected with a circumferentially extending seal, then connection is achieved, but installation space requirements increase
Solution Approach 1:
The patent transitions from axial connection methods to a radial/dimensional approach by creating a common interface region where bellows adjoin laterally. This dimensional change allows the connection to be made in the radial direction rather than requiring additional axial length, reducing installation space while maintaining connection reliability.
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 design improves mechanical load resistance, reduces installation space requirements, and facilitates efficient recycling, while maintaining effective filtration performance and handling during servicing.
Implementation Method 1
a circumferentially extending seal present in the interface region which connects the two filter bellows directly by material fusion to each other
Data Source
AI summary
A filter element has two filter bellows adjoining each other in an interface region between the outflow surface of one of the filter bellows and the inflow surface of the other. A circumferential seal in the interface region connects the filter bellows by material fusion. In transverse direction to the flow direction, one filter bellows has a small extension and the other a large extension larger than the small extension. The filter bellows are arranged such that, along an edge of the filter bellows with large extension, a free space in the interface region of the filter bellows with the large extension is not covered by the filter bellows with the small extension. In the free space region, the seal is connected by material fusion to the filter bellows with the large extension. A filter device with a two-part housing contains such a filter element.