Variable Pleat Height Filter Element for Compact Engine Air Intake
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Solution Overview
Problem
Existing filter systems for internal combustion engines face challenges in achieving a high separation rate for dust particles while maintaining a compact installation space, as they often require a compromise between filter surface area and outlet cross-section.
Innovation Solution
A filter system with a zigzag-folded filter medium and a secondary element, where the filter medium has variable flow resistance along the longitudinal axis, allowing for effective particle separation with reduced installation space and improved air guidance, featuring a semi-conical fold design that reduces fold height on the outlet side and includes a cyclone separator for pre-separation of dirt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pleat height of the filter medium is increased to achieve a large effective filter area, then the separation rate for dust particles is improved, but the outlet opening cross-section is reduced leading to increased flow resistance
Solution Approach 1:
The filter medium is designed with locally varying properties: the pleat height varies along the longitudinal axis, being larger in the inlet region and smaller in the outlet region. This local variation allows the inlet area to provide high separation efficiency while the outlet area maintains low flow resistance, resolving the contradiction between separation rate and energy loss
Solution Approach 2:
The pleat height parameter of the filter medium is changed continuously or in steps along the longitudinal axis. By transitioning from high pleat height at the inlet to low pleat height at the outlet, the system achieves both high separation rate where needed and low flow resistance where required, eliminating the need for compromise
2Volume of moving object
If a cylindrical filter element design is used to maintain compact dimensions, then the installation space is reduced, but the outlet opening cross-section is limited by the interior diameter
Solution Approach 1:
The filter element transitions from a simple cylindrical design to a conical design, utilizing the radial dimension to increase the outlet opening cross-section. The conical shape allows the outlet diameter to be larger than what would be available in a cylindrical element of the same external dimensions, reducing flow resistance while maintaining compact installation space
3Loss of energy
If the outlet opening cross-section is increased to reduce flow resistance, then the energy loss is reduced, but the filter area is decreased leading to lower separation rate
Solution Approach 1:
The filter element is segmented into different functional zones along the longitudinal axis: an inlet zone with high pleat height for separation and an outlet zone with low pleat height for flow discharge. This segmentation allows each zone to optimize for its specific function, achieving both high separation rate and low flow resistance simultaneously
Solution Approach 2:
Different regions of the filter medium have different pleat heights tailored to their specific functions. The inlet region has high pleat height for maximum separation area, while the outlet region has low pleat height for minimum flow resistance, allowing both contradictory requirements to be satisfied in different locations
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
This configuration achieves a high separation rate for dust particles with reduced pressure loss and extended service life of the filter element, while maintaining a compact design suitable for demanding conditions like construction and agricultural machinery.
Implementation Method 1
a filter system with a filter element, in particular for use as an air filter of an internal combustion engine
Implementation Method 2
the filter system comprising a cyclone separator (36) arranged in the housing (108)
Data Source
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AI summary
The invention relates to a filter system (100) with one or more filter elements (10, 12) equipped with at least one filter medium (56), wherein at least one filter element (10) extends along a longitudinal axis (L). The filter system (100) comprises a housing (108) with a housing wall (112) and a cover (110), an inlet (102) arranged on the housing (108) for supplying a fluid to be filtered, in particular air, and an outlet (104) arranged on the housing (108) for discharging the filtered fluid. The filter medium (56) is folded in a zigzag pattern and has a plurality of outer edges (70) extending along the longitudinal axis (L) and inner edges (72) of folds (62) opposite the outer edges (70) on the opposite side of the filter medium (56). Furthermore, the filter medium (56) exhibits a flow resistance that varies along the longitudinal axis (L).The invention further relates to a filter element (10) with such a filter medium (56) for interchangeable installation in such a filter system (100).