Abstract:
A filter for internal combustion engine air intake comprised of a synthetic fiber media uniquely enhanced with a gradient density configuration. The media described in this application is a low restriction synthetic fiber media enhanced with gradient density configuration to greatly improve efficiency and dust holding capacity. The invention is for use and configuration for use in engine intake air filtration.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    A filter for internal combustion engine air intake comprised of a synthetic fiber media uniquely enhanced by virtue of its gradient density characteristics. 
         [0003]    The ideal filter media would be one that has a very high initial efficiency, very low restriction to flow and a high dust holding capacity for long service life. 
         [0004]    2. Summary of the Prior Art 
         [0005]    Common engine air filters are typically constructed of cellulose fiber or synthetic fiber based media, with cellulose media typically having higher restriction to flow and lower dust holding capacity but having higher cleaning efficiency. Synthetic fiber media is often constructed to have lower restriction to flow but can hold more contaminant before becoming restrictive but at a lower cleaning efficiency. 
         [0006]    Either of these media can be configured to improve any one of their performance characteristics but always at the expense of some other performance area. Spreading the fibers can reduce restriction but it also reduces efficiency. Using finer fibers closer together can increase efficiency without excessive increases in restriction but the dust holding capacity decreases dramatically. 
         [0007]    All standard, non-enhanced media efficiencies begin at their lowest levels when they are new and clean (commonly referred to as initial efficiency) and then will gain efficiency as they accumulate dust. These collected dust particles actually form a barrier on the surface of the filter fibers but until those particles form on the filter the media performs poorly. 
       SUMMARY OF THE INVENTION 
       [0008]    The media described in this application is a low restriction synthetic fiber media enhanced by a gradient density configuration to greatly improve efficiency and dust holding capacity. 
         [0009]    The media is nonwoven. It has a progressively finer/higher fiber density starting from the outside dirt air side moving in toward the clean air side. The target dust can penetrate deeply into the media using more than simply the upstream surface area to be captured by the media. The depth loading of the media is greatly enhanced. 
         [0010]    This invention is for its use and configuration for use in engine intake air filtration. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0011]    This gradient density engine air filter is a new innovative concept which provides the most effective solution in filtering particulates down to 0.05 microns in size. 
         [0012]    Typical filter media used to remove particles at this smallest size fraction require the use of extremely fine fibers. These materials, whilst often achieving high efficiencies, are usually associated with the inherent disadvantages of low dust holding capacity and high resistance to air flow. 
         [0013]    The gradient density configuration which give the benefit of a high dust loading capacity, low air flow resistance and high efficiencies against sub-micron particles. 
         [0014]    This new gradient density filter offers flexibility to fabricators whilst meeting their specific filtration requirements. It is this flexibility that allows lamination to a variety of different substrates. This imparts additional properties such as palatability, odor removal and mouldability. 
         [0015]    This new filter media can be supplied in rolled, sheet, cut pad or pleated forms. 
         [0016]    A high efficiency low restriction filter media for use as an engine intake air filter is disclosed. The media is comprised of synthetic fibers, primarily polyester, with the fiber density increasing in progression from the air entering side to the air leaving side of the media. Fibers are thermally bonded to create a fiber matrix of high strength and high air permeability capable of high particle removal efficiency and dust holding capacity. 
         [0017]    Drawing  FIG. 3  illustrates a gradient density embodiment where the density gradients are somewhat discrete. In other embodiments, the density gradients vary in a non-discrete, uniform manner. 
         [0018]    The media as disclosed has a weight of approximately 230 grams per meter squared, a thickness in the direction of flow of approximately 3.0 millimeters and an air permeability of approximately 1,100 liters per square meter per second at a restriction of two millibars. 
         [0019]    A typical filtration media of similar physical construction when tested using the ISO 5011 testing protocol and fine test dust as the challenge particulate at a media velocity between 60 to 80 feet per minute will achieve an initial collection efficiency of less than 90 percent, and a cumulative efficiency of less than 95 percent with a dust holding capacity of less than 150 grams. 
         [0020]    The inventive media at these conditions will achieve an initial efficiency greater than 98 percent, a cumulative efficiency greater than 99 percent, and a dust holding capacity greater than 300 grams. 
         [0021]    Having thermally bonded fibers creates a semi-rigid media so when configured in a pleated configuration as typically constructed, no additional supporting screen needs to be co-pleated with the media to support the pleated structure. The omission of the co-pleated screen reduces restriction through the media and reduces cost of fabrication. 
         [0022]    The inventive media supports the acoustic behavior of an engine air duct, provides high thermal and mechanical stability, especially under pulsating forces. Additionally, good elasticity in crash tests is exhibited. 
         [0023]    This new media is resistant to water, engine oils, fuel fumes, and chemicals, and shows a high aging resistance. The progressive gradient structure can be enhanced by a microfiber barrier layer on the downstream side. This results in higher dust collection efficiency rates, especially useful in turbo diesel engines and other engines having high airflow rates. 
         [0024]    The fiber structure is mechanically and thermally bonded. Stiffening treatments are unnecessary. The media satisfies the flame retardant class F1 according to DIN53438. 
         [0025]    The media is a depth loading filter as compared to surface loading filter such as cellulose paper. In the present invention, the majority of dust is trapped in the depth of the media, fine particles penetrating deeper into the media and coarse particles collected closer to the upstream side. This selective distribution of dust particles in the media maintains a high air permeability which optimizes pressure drop problems for the lifetime of the filter. Prior art paper filters collect dust particles on the upstream side with little penetration into the media. This builds up a dust layer on the upstream side creating faster pressure drop. 
         [0026]    With the present invention, the filter element can be reduced to one-third to one-quarter of the size of a comparable cellulose paper filter. The filter element weight can also be decreased by 20 to 40 percent. 
         [0027]    In a test subjecting filters to water, the inventive media showed no change in shape or tensile strength after 72 hours under wet conditions, but the paper media showed a 70% decrease in tensile strength. 
         [0028]    The inventive media overcomes the deficiencies of cellulose paper because of its irreversibly thermally bonded structure. No dust breaks through on the downstream side during engine pulsation. This improved performance is due to the strong density of the downstream side of this new media. 
         [0029]    An additional benefit is that in one embodiment a single polymer fiber is used, so the filter is environmentally friendly and easily disposed. 
         [0030]    It can be any thickness, however current technology requires thickness of approximately 0.060″-0.100″ to be suitable for engine intake air filtration. The current product in development uses approximately 0.080″ thick material. 
         [0031]    It is not necessary to co-pleat the media. However, an outside and/or inside mesh be utilized. A new and inventive hexagonal shaped mesh material may be employed. The hexagonal shape allows for an improvement in open area from 60% for round, perforated mesh to 80% for new hexagonal mesh. 
         [0032]    However, the media may be co-pleated with aluminum wire mesh support on both sides in a variety of pleat heights. Wire mesh is used to support media, however other methods may be employed such as a pleatable plastic mesh laminate backing. 
         [0033]    The filter configuration may be cylindrical, oval, frustro-conical, or flat panels in any aspect ratio. Media may be potted into molded endcaps that also comprises of the filter seal, utilizing a resin material such as polyurethane or a plastisol. Or it may be potted with a similar resin material into an end cap composed of any type of metal or composite using a separate gasket material to create a positive seal. The filter is designed to be cleanable with a compressed air nozzle utilizing shop air blown from the downstream side of the media out toward the upstream side and then reused with minimal loss of performance. 
         [0034]    The invention integrates this type of filter media into engine air filters, particularly automotive air filtration. 
         [0035]    Table 1 
         [0036]    The following are some tables illustrating characteristics of the invention: 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                 Inventive 
                   
                   
               
               
                 Media 
                 Nonwoven 
               
               
                 Characteristics 
                 Material 
                 Cellulose Paper 
                 Multilayer Foam 
               
               
                   
               
             
             
               
                 Thickness 
                 3.0 
                 Less than 1.0 
                 Greater than 10 
               
               
                 (millimeters) 
               
               
                 Weight (g/m 2 ) 
                 230-250  
                 100-120 
                 100-200 
               
               
                 SAE Coarse 
                 900-1300 
                 190-300 
                 250-350 
               
               
                 Holding Capacity 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
             
               
             
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
             
             
               
                 CONSTRUCTION 
               
             
          
           
               
                   
                 Fiber 
                 Treatment 
                 Weight 
               
               
                   
                   
               
               
                   
                 Polyester 
                 thermally bonded 
                 app. 230 g/m 2   
               
               
                   
                   
               
             
          
           
               
                 TECHNICAL DATA 
               
             
          
           
               
                   
                 Parameter 
                 Value 
               
               
                   
                   
               
             
          
           
               
                   
                 Weight 
                 230 +/− 25 
                 g/m 2   
               
               
                   
                 Thickness 
                 3.0 +/− 0.3 
                 mm 
               
               
                   
                 Air Permeability at 2 mbar 
                 1100 +/− 100 
                 l/m 2 s 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
             
               
             
               
               
               
             
               
               
               
               
               
             
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
             
             
               
                 The Invention 
               
             
          
           
               
                   
                 CFM 
                 D.P. 
                 Dust Feed 
                 Minutes 
               
               
                   
                   
               
               
                   
                 400 
                 7.8 
                 0 
                 0 
               
               
                   
                 400 
                 7.9 
                 11.33 
                 1 
               
               
                   
                 400 
                 8 
                 22.66 
                 2 
               
               
                   
                 400 
                 8.1 
                 33.99 
                 3 
               
               
                   
                 400 
                 8.2 
                 45.32 
                 4 
               
               
                   
                 400 
                 8.3 
                 56.65 
                 5 
               
               
                   
                 400 
                 8.5 
                 67.98 
                 6 
               
               
                   
                 400 
                 8.7 
                 79.31 
                 7 
               
               
                   
                 400 
                 8.9 
                 90.64 
                 8 
               
               
                   
                 400 
                 9.2 
                 101.97 
                 9 
               
               
                   
                 400 
                 9.5 
                 113.3 
                 10 
               
               
                   
                 400 
                 9.7 
                 124.63 
                 11 
               
               
                   
                 400 
                 10 
                 135.96 
                 12 
               
               
                   
                 400 
                 10.35 
                 147.29 
                 13 
               
               
                   
                 400 
                 10.6 
                 158.62 
                 14 
               
               
                   
                 400 
                 11 
                 169.95 
                 15 
               
               
                   
                 400 
                 11.45 
                 181.28 
                 16 
               
               
                   
                 400 
                 11.75 
                 192.61 
                 17 
               
               
                   
                 400 
                 12.25 
                 203.94 
                 18 
               
               
                   
                 400 
                 12.7 
                 215.27 
                 19 
               
               
                   
                 400 
                 13.1 
                 226.6 
                 20 
               
               
                   
                 400 
                 13.55 
                 237.93 
                 21 
               
               
                   
                 400 
                 13.9 
                 249.26 
                 22 
               
               
                   
                 400 
                 14.4 
                 260.59 
                 23 
               
               
                   
                 400 
                 14.9 
                 271.92 
                 24 
               
               
                   
                 400 
                 15.5 
                 283.25 
                 25 
               
               
                   
                 400 
                 16.2 
                 294.58 
                 26 
               
               
                   
                 400 
                 16.75 
                 305.91 
                 27 
               
               
                   
                 400 
                 17.2 
                 317.24 
                 28 
               
               
                   
                 400 
                 17.7 
                 328.57 
                 29 
               
               
                   
                 400 
                   
                   
                 30 
               
               
                   
                   
               
             
          
           
               
                 Terminate @ (Initial D.P. + 10) = 17.8 w.g. 
               
             
          
           
               
                 20 g fed at 1:45 elapsed: 
               
               
                   
               
             
          
           
               
                   
                 ABS Filter 
                 137.36 
               
               
                   
                 GAIN 
                 0.18 
               
               
                   
                   
               
             
          
           
               
                   
                   
                 ABS Filter 
                 Element 
                 Total Fed 
               
               
                   
                   
               
               
                   
                 After 
                 138.2 
                 1077 
               
               
                   
                 Before 
                 137.18 
                 754 
               
               
                   
                 GAIN 
                 1.02 
                 323 
                 324.02 
               
               
                   
                   
               
             
          
           
               
                   
                 Initial Efficiency (1 − (A/20)) × 100 
               
               
                   
                 99.1 
               
               
                   
                 Cumulative Efficiency (1 − (B/D)) × 100 
               
               
                   
                 99.7 
               
               
                   
                 Dust Holding Capacity (C) 
               
               
                   
                 323   
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
             
               
             
               
               
               
             
               
               
               
               
               
             
               
               
             
           
               
                 TABLE 4 
               
               
                   
               
             
             
               
                 Cellulose 
               
             
          
           
               
                   
                 CFM 
                 D.P. 
                 Dust Feed 
                 Minutes 
               
               
                   
                   
               
               
                   
                 400 
                 7.8 
                 0 
                 0 
               
               
                   
                 400 
                 8.4 
                 9.81 
                 1 
               
               
                   
                 400 
                 9.4 
                 19.62 
                 2 
               
               
                   
                 400 
                 10.6 
                 29.43 
                 3 
               
               
                   
                 400 
                 11.9 
                 39.24 
                 4 
               
               
                   
                 400 
                 13.2 
                 49.05 
                 5 
               
               
                   
                 400 
                 14.8 
                 58.86 
                 6 
               
               
                   
                 400 
                 15.9 
                 68.67 
                 7 
               
               
                   
                 400 
                 17.3 
                 78.48 
                 8 
               
               
                   
                 400 
                 17.8 
                 82 
                 8.4 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                   
               
             
          
           
               
                 Terminate @ (Initial D.P. + 10) = 17.8 w.g. 
               
             
          
           
               
                 20 g fed at 1:45 elapsed: 
               
               
                   
               
             
          
           
               
                   
                 ABS Filter 
                 52.03 
               
               
                   
                 GAIN 
                 0.34 
               
               
                   
                   
               
             
          
           
               
                   
                   
                 ABS Filter 
                 Element 
                 Total Fed 
               
               
                   
                   
               
               
                   
                 After 
                 52.09 
                 885 
               
               
                   
                 Before 
                 51.69 
                 803 
               
               
                   
                 GAIN 
                 .4 
                 82 
                 82.4 
               
               
                   
                   
               
             
          
           
               
                   
                 Initial Efficiency (1 − (A/20)) × 100 
               
               
                   
                 98.5 
               
               
                   
                 Cumulative Efficiency (1 − (B/D)) × 100 
               
               
                   
                 99.5 
               
               
                   
                 Dust Holding Capacity (C) 
               
               
                   
                 82 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
             
               
             
               
               
               
             
               
               
               
               
               
             
               
               
             
           
               
                 TABLE 5 
               
               
                   
               
             
             
               
                 COTTON GAUZE 
               
             
          
           
               
                   
                 CFM 
                 D.P. 
                 Dust Feed 
                 Minutes 
               
               
                   
                   
               
               
                   
                 400 
                 7.3 
                 0 
                 0 
               
               
                   
                 400 
                 7.3 
                 11.33 
                 1 
               
               
                   
                 400 
                 7.4 
                 22.66 
                 2 
               
               
                   
                 400 
                 7.4 
                 33.99 
                 3 
               
               
                   
                 400 
                 7.6 
                 45.32 
                 4 
               
               
                   
                 400 
                 7.8 
                 56.65 
                 5 
               
               
                   
                 400 
                 8 
                 67.98 
                 6 
               
               
                   
                 400 
                 8.2 
                 79.31 
                 7 
               
               
                   
                 400 
                 8.8 
                 90.64 
                 8 
               
               
                   
                 400 
                 10.2 
                 101.97 
                 9 
               
               
                   
                 400 
                 11.5 
                 113.3 
                 10 
               
               
                   
                 400 
                 13.3 
                 124.63 
                 11 
               
               
                   
                 400 
                 18.1 
                 146.4 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                 400 
               
               
                   
                   
               
             
          
           
               
                 Terminate @ (Initial D.P. + 10) = 17.3 w.g. 
               
             
          
           
               
                 20 g fed at 1:45 elapsed: 
               
               
                   
               
             
          
           
               
                   
                 ABS Filter 
                 54 
               
               
                   
                 GAIN 
                 2.09 
               
               
                   
                   
               
             
          
           
               
                   
                   
                 ABS Filter 
                 Element 
                 Total Fed 
               
               
                   
                   
               
               
                   
                 After 
                 58.31 
                 757 
               
               
                   
                 Before 
                 51.91 
                 617 
               
               
                   
                 GAIN 
                 6.4 
                 140 
                 146.4 
               
               
                   
                   
               
             
          
           
               
                   
                 Initial Efficiency (1 − (A/20)) × 100 
               
               
                   
                 90.8 
               
               
                   
                 Cumulative Efficiency (1 − (B/D)) × 100 
               
               
                   
                 95.6 
               
               
                   
                 Dust Holding Capacity (C) 
               
               
                   
                 140 
               
               
                   
                   
               
             
          
         
       
     
     
    
     BRIEF DESCRIPTION OF THE FIGURES 
       [0037]      FIG. 1 . A Graph of Restriction Versus Dust Fed 
         [0038]      FIG. 2 . Airflow resistance 
         [0039]    Airflow resistance for Technostat weights from 50 to 500 g/m 2  against media velocities from 0.05 to 0.3 m/sec. 
         [0040]      FIG. 3 . Gradient Density Engine Intake Filter. 
         [0041]      FIG. 4 . Top View of Filter. 
         [0042]      FIG. 5 . Outlet View of Filter. 
         [0043]      FIG. 6 . Side View of hexagonal support mesh.