Zigzag Filter Element With Ultrasonic Embossed Bonding
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Solution Overview
Problem
Existing filter elements for internal combustion engines face challenges in precisely connecting and folding multi-layer filter media, leading to instability and reduced filtration efficiency.
Innovation Solution
The filter medium is embossed to create additional functional areas for bonding layers together, using material connections such as welding or adhesives, which enhances stability and filtration performance while minimizing the area affected by embossing and connections, allowing for the combination of different materials and structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filter medium is embossed to create additional functional areas for bonding layers together, then the stability and filtration efficiency are improved, but the area of the filter medium that can be impaired by embossings and connections increases
Solution Approach 1:
The embossing is applied locally only in specific sections of the filter medium where functional areas are needed for bonding layers, rather than across the entire surface. This localized approach allows the filter medium to maintain its filtration functionality in non-embossed areas while gaining stability and structural integrity in the embossed sections where material connections are formed.
2Stability of the object's composition
If multiple layers are embossed and bonded to one another, then the stability of the filter medium in the folded state is increased, but the production complexity increases
Solution Approach 1:
The embossing process and the material connection process are merged into a single integrated operation. The embossing creates functional areas that are simultaneously used for bonding multiple layers together, eliminating the need for separate embossing and bonding steps. This reduces production complexity while achieving enhanced stability in the folded state through multi-layer bonding.
3Manufacturing precision
If the filter medium is folded along fold lines with material connections, then the folding precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The fold lines are embossed in advance during the embossing process, creating predetermined folding lines with functional areas for material connections. This preliminary embossing action prepares the filter medium for precise folding by establishing the exact locations and characteristics of fold lines before the actual folding operation, thereby improving folding precision while integrating the preparation step into the existing embossing process.
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 approach improves the stability and filtration efficiency of the filter element, extends its service life, and simplifies the production process by integrating embossing and material connection in a single step, optimizing the active filtration area and maintaining fluid flow.
Implementation Method 1
A multi-layer, web-shaped filter medium is used for production, which is folded to form the filter element. The filter medium is fed by means of a feed device to a heat-introducing embossing unit, in particular an ultrasonic embossing unit, which embosses fold lines in the filter medium.
Implementation Method 2
When embossing, layers of the multi-layer filter medium are welded along the fold lines using the heat-transferring embossing unit.
Implementation Method 3
a heat-introducing embossing unit, in particular an ultrasonic embossing unit
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A filter element (13), particularly for an internal combustion engine, particularly for a motor vehicle, a device, and a method for manufacturing a zigzag-folded filter element (13) are described. The filter element (13) comprises a filter medium (12) consisting of a media web made of several layers and folded along fold lines (36). The filter medium (12) is embossed in at least one section (37) between adjacent fold lines (36) in at least one further functional area (39). The layers of the multilayer filter medium (12) are bonded together along the embossing of the at least one functional area (39).