Multilayer Waved Filter Element with Alignment Features
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Solution Overview
Problem
Air cleaners for combustion engines and air compressor systems face challenges in filtration efficiency and support structures, particularly for horizontally mounted primary elements and alignment of safety elements, leading to issues with dust loading and improper installation.
Innovation Solution
A filter element design featuring a multilayer laminate media construction with a filtration media layer in a waved configuration, supported by fibrous layers and a cover layer, and end caps that provide structural support and alignment features, including a seam for enhanced durability and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional filter element design is used, then the structure is simple, but the filtration efficiency is insufficient and dust loading occurs
Solution Approach 1:
The patent applies composite materials by constructing the filter media as a multilayer laminate comprising a filtration media layer, a support layer, and a cover layer. Each layer serves a specific function: the filtration media layer captures particles, the support layer maintains structural integrity, and the cover layer protects the internal structure. This composite construction enhances filtration efficiency while managing the complexity through functional differentiation.
Solution Approach 2:
The patent employs curvature by forming the filtration media layer in a waved or pleated configuration rather than a flat structure. This curved arrangement significantly increases the surface area of the filtration media, allowing for greater particle capture capacity and improved filtration efficiency without proportionally increasing the axial length of the filter element.
2Volume of moving object
If the filter element is horizontally mounted, then space utilization is improved, but alignment and support issues arise
Solution Approach 1:
The patent incorporates pre-formed alignment features including a protrusion on the filter element that engages with a corresponding recess in the air cleaner housing. This preliminary alignment structure ensures proper positioning of the filter element during installation, eliminating alignment issues even when the element is horizontally mounted, and simplifies the installation process.
Solution Approach 2:
The patent addresses horizontal mounting challenges by adding dimensional features in the radial direction, such as the protrusion-recess alignment mechanism and the laterally extending support structure. These features provide stability and proper orientation in the horizontal plane, enabling effective space utilization while maintaining ease of installation and alignment.
3Ease of operation
If the safety element is misplaced, then installation is simplified, but filtration performance deteriorates
Solution Approach 1:
The patent incorporates pre-formed alignment features including a protrusion on the filter element that engages with a corresponding recess in the air cleaner housing. This preliminary alignment structure ensures proper positioning of the filter element during installation, eliminating alignment issues even when the element is horizontally mounted, and simplifies the installation process.
4Reliability
If a multilayer laminate construction is implemented, then filtration efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the filter media into distinct functional layers: a filtration media layer for particle capture, a support layer for structural maintenance, and a cover layer for protection. This segmentation allows each layer to be optimized independently for its specific function, achieving high filtration efficiency while managing manufacturing complexity through modular construction.
Data Source
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AI summary
A filter element is provided according to the present invention. The filter element includes: (a) a media pack arrangement having first and second opposite ends, said media pack arrangement comprising: (i) an inner liner defining a safety central open volume; (ii) a multilayer laminate media construction circumscribing the inner liner and having a first end and a second end, wherein the multilayer laminate media construction comprises: (A) a filtration media layer arranged in a waved configuration, wherein the filtration media layer has a first side and a second side; (B) a first fibrous support layer adjacent the first side of the filtration media layer arranged in the waved configuration; (b) a first end cap at the first end of the media pack arrangement; said first end cap having a central aperture in flow communication with said safety central open volume; and (c) a second end cap at the second end of the media pack arrangement; said second end cap being a closed end cap. An air cleaner is provided, and a media pack is provided.