Customized air filter designs with Flexline

The better utilization of automobile installation space has a number of different advantages, particularly higher filtration performance thanks to better dust holding capacity, also reduced pressure loss and enhanced acoustics. MANN+HUMMEL is showing alternatives to conventional air filter element shapes at the booth F 12 in hall 11.1 of MANN+HUMMEL at FILTECH.

In an engine compartment installation space is precious and limited. Performance components, such as turbocharging, diesel particle filters and much more have drastically reduced the available space under the hood in the last decades. Better utilization of the design space given by the OEMs is required to fulfill their increasing demands on engine air filter systems. This has resulted in designers and engineers now having to haggle over a matter of millimeters of space. To tackle this issue, filter specialist MANN+HUMMEL has developed Flexline, a new generation of air filters which utilize installation space with even greater efficiency thanks to the enhanced flexibility of its external contours. The result is a compact, performance-enhanced filter with a variable design according to the installation space specification. Laser cutting makes it all possible. It is also possible, for example, to relocate the clamping elements (such as clips or screws) to the inside of the air cleaner system in order to reduce the external contours and avoid collisions with other elements in the installation space.

Innovative filter element and housing go hand in hand, as the now fits into the available installation space of the engine compartment. Panel air filters based on rectangular, trapezoidal and polygonal forms with straight lateral edges were once the dominant design. Now, Flexline can make maximum use of installation spaces thanks to its curved external contours. Unlike conventional designs, Flexline components therefore have a larger flow surface. This provides new scope for development to achieve targeted improvements in the filtration characteristics or pressure loss.

With an innovative, Flexline elements are also flatter than conventional products. On the one hand, this facilitates a flatter housing. On the other, the gain in installation space can be utilized to increase the pleat height.

More freedom for development with Flexline

Flexline – thanks to its improved utilization of installation space - increases filtration surface or reduces pressure loss. One or the other as well as a combination of both development strategies are possible here. A larger filtration area increases lifetime whilst simultaneously reducing pressure loss. The other development approach, namely to increase pleat distance, leads to a significant pressure loss reduction with the same service life.

The Flexline concept offers one further advantage in terms of optimization of the intake system. The acoustics, in other words minimization of undesirable noises, are improved by an increased air filter housing volume. In addition, the resulting larger housing cross section offers additional potential for further reduction of the noise occurring in the intake system.

Element designs can have cut outs not only on the front edge side, all sides of the bellow outer contour can be cut. Additionally, round or oval holes can be implemented within the outer edges of the bellow. The filter element geometry can be adapted to the available design space in the engine compartment. The filter element can follow the shape of larger interfering contours like strut domes or bypass smaller parts like screws.

Printed on 2019-02-23