Wedge-Shaped Compressible Filter Element for Engine Intake
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Solution Overview
Problem
Existing filter elements for engine intake air filtration in motor vehicles occupy too much space due to their compact design, limiting their installation in modern vehicles and posing a risk of injury during accidents due to their rigidity.
Innovation Solution
A wedge-shaped filter element with inclined components and a nonwoven fabric filter medium that can be compressed, allowing for space-saving installation and improved deformability to reduce the risk of injury.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If filter elements are designed as compact cartridges with parallel end caps, then filtration function is achieved, but installation space becomes too large for modern vehicles
Solution Approach 1:
The patent applies asymmetry by transitioning from symmetric parallel end caps to asymmetric inclined end caps. The first end cap is inclined relative to the second end cap, creating a wedge-shaped filter element that reduces volume while maintaining filtration function. This asymmetric configuration allows the filter to fit into tight, irregular installation spaces in modern vehicles.
Solution Approach 2:
The patent utilizes dimensional change by introducing an angular/tilt dimension to the end cap configuration. Instead of only axial compression, the inclined end caps create a three-dimensional wedge shape that optimizes space utilization in multiple directions, allowing the filter to fit into constrained installation environments.
2Stability of the object's composition
If filter elements use rigid compact design, then structural stability is maintained, but deformability during accidents is insufficient causing injury risk
Solution Approach 1:
The patent applies parameter changes by modifying the material properties of the filter medium from traditional rigid materials to compressible nonwoven fabrics. This material parameter change enables the filter to deform under impact forces during accidents, reducing injury risk to occupants while maintaining structural integrity during normal operation.
Solution Approach 2:
The patent implements dynamics by enabling the filter element to transition from a static rigid structure to a dynamic compressible structure. The inclined end caps combined with compressible nonwoven fabric allow the filter to adapt its shape and volume during accidents, absorbing impact energy and reducing harmful effects on vehicle occupants.
3Volume of stationary object
If wedge-shaped design with inclined end caps is used, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the filter element into distinct modular components: first end cap, second end cap, and filter medium. This segmentation allows each component to be manufactured separately using standard processes, then assembled together. The inclined end caps can be produced using conventional molding techniques, reducing overall manufacturing complexity despite the wedge shape.
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 wedge-shaped design enables efficient use in tight spaces, and the nonwoven fabric ensures effective filtration while allowing for reversible deformation, reducing the risk of injury and maintaining filter performance.
Implementation Method 1
a filter medium which forms a peripheral wall surface (5) through which a fluid for filtering can pass
Implementation Method 2
the filter medium is made of a nonwoven fabric and folded in such a way that a distance between the components can be reversibly reduced, at least in some areas, when force is applied to them
Implementation Method 3
the nonwoven fabric ensures effective filtration while allowing for reversible deformation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The filter element has two components (1,2) and a filter medium (3) arranged between the components. The components are spaced apart by the filter medium. The components are oriented with each other in an inclined manner or have inclined surfaces. The components are limited at two inclined levels of the filter medium with each other. The filter medium has different height at different places. The filter medium is made of a thermoplastic fleece material.