Air filters are to do an important job, namely to stop solid particles such as mineral dust, soot and organic particles that are omnipresent in the air sucked in by the engine. Thanks to the technological progress in the field of filter construction design and the applied filtering media, the now manufactured air filters show the efficiency of filtering the impurities at the level of 99.9% for the particles as small as several micrometers. Because engines consume huge amounts of air at combustion (about 10 m³ of air per 1 litre of fuel on average), high filter efficiency at minimum flow resistance is an extremely important parameter. Thanks to such parameters the filter life can be extended. Air filters presently applied in motor vehicles are characterized with a varied construction and are manufactured from different, optimally selected materials. All the filters of this type are composed of a removable casing and replaceable filter insert, their construction design is presented in Figure no 1.
The filter bag made of resin saturated flimsy fabric is hot moulded in a furnace, during the process the resin undergoes curing. To retain the shape of the folds, during the moulding process, a streak of thermo adhesive, composed of mainly polyesters or polyamides, is applied.
Fig. 1 Construction scheme of a panel air filter: filtering compartment - bag, moulded during the plasticizing of the flimsy fabric; adhesive streak - made of thermo glue, to retain the bag shape, sealing - polyurethane seal, fixed onto the bag
WIX-FILTRON Sp. z o.o. was the world pioneer in the new method of the application of the adhesive streak by using the expanded glue. The project was co-financed under the EU Operational Programme "Innovative Economy", Activity 4.4., as a result of the project completion, the production of new quality panel air filters was launched. The design innovation is confirmed with the patent registration for "Filter bag for air or fluid filters and its manufacturing process", file no P.387709, whose scope is the production of filter bags stabilized with expanded glue.
The implemented design project shall positively affect the sustainable development as it will reduce the adverse effect of businesses upon the natural environment. It consists in launching automated filter production lines, provided with robots that are to apply the mould separating media, filter receipt and positioning buffer to receive and position filters after the polyurethane seal moulding and a set of 2 robots to cut the machining polyurethane allowance. Moreover, expanded thermo glue applicators (extruders) and flimsy fabric curing furnace have been introduced.
The implemented technologies are environmentally friendly as they reduce the number of materials used for the production of filters and the amount of the generated production waste.
From the perspective of the user and the environment, the positive influence of the design upon the filter efficiency in its entire life is an important element of the project. Stiffening of the filter bag and the non-variable parameters, ensured thanks to the application of the expanded glue, guarantees even and stable layout of folds in any exploitation conditions. The new bag construction prevents the collapse effect of the folds (splicing), thanks to that, over the entire filter life, its efficiency is not reduced due to the shrinkage of the filtering surface area. This crucially affects the composition of the fuel mixture supplied to the vehicle engine (the more oxygen it contains, the better), and thus it affects the consumption of fuel and the decomposition rate of high molecular hydrocarbons (including aromatic hydrocarbons).
The inscription „PRO ECO Filters" Environmentally Friendly Technology” is placed on all such filter boxes, which clearly informs the client that buying this product, he/she supports the environmental protection.
Below, we have listed the innovative panel air filters (and their application) implemented into production within the project:
"Diversification of production through the implementation of the innovative panel air filters production technology" executed thanks to co-financing from the EU funds within the Operating Program "Innovative Economy".
|Filtron No.||Basic Application:|
|AP 004/3||Audi Q7; VW Touareg; Porsche Cayenne|
|AP 004/4||Audi A3 II, TT II; Volkswagen Eos, Golf V, Passat 3.2i FSI V6, 3.6FSI|
|AP 023/3||Ford Transit 2.0D 16V, 2.0TD 16V, 2.4D 16v, 2.4TD 16V (DuraTorq) 8/00->|
|AP 025/1||BMW 135i (E82/E88), 335i,xi (E90/E91/E92), Z4 3.5 (E89)|
|AP 032/1||BMW 750 (E38)|
|AP 034/1||Mercedes A (W169) 9/04->, B (W245) 4/05->|
|AP 034/5||Mercedes B (W246)|
|AP 051/4||Opel Astra II, Astra III, Zafira 1.7DTI, 2.0DTI 8/01->|
|AP 051/5||Opel Combo B, Corsa C 1.3CDTI, 1.7DTI 9/00->|
|AP 051/6||Opel Astra H 1.9CDTI 9/04->|
|AP 058/4||Citroen C4 2.0i 16V 10/04-->, C4 Picasso; Peugeot 307 2.0i 16V 4/05-->|
|AP 114||Mazda 626 2.0|
|AP 118/3||Mercedes S (W220) 10/98->|
|AP 118/7||Mercedes E200, E220D, E240V6, E280V6, E320V6 8/99->|
|AP 129/5||Landrover Defender 2.4D 07-->|
|AP 137/3||Nissan Primastar, Opel Vivaro, Renault Trafic II 2.5DCI|
|AP 137/4||Renault Master 2.2DCI, 2.5DCI 11/03-->|
|AP 139/2||Audi A3 II 1.9TDI, 2.0TDI 5/03->; VW Golf V, Touran 1.9TDI, 2.0TDI 3/03->|
|AP 139/4||Audi A4 II 1.8TFSI, 2.0TDI 11/07-->, A5 1.8TFSI 10/07-->|
|AP 149||Volvo 850 Series|
|AP 149/1||Audi A3; Seat Toledo II; Skoda Octavia; VW Golf IV 1.6i, 1.8i 20V, 2.3GTi, Bora|
|AP 149/5||Audi A3; Seat Toledo II; Skoda Octavia; VW Golf IV 1.6i, 1.8i 20V, 2.3GTi, Bora|
|AP 149/8||Audi A3 2.0TFSI (AXX); Skoda Octavia II 2.0RS; VW Golf V 2.0GTI (BWA,BPY)|
|AP 149/10||Volkswagen Jetta II 2.5 V5|
|AP 150/1||Ford Fiesta V, Fusion 1.6 TDCI 11/04-->|
|AP 152/3||Opel Insignia|
|AP 154/3||Nissan Navara 2.5DCI|
|AP 157/6||VW Golf 1.1 -->8/83, Passat 1.3 -->8/83, Polo 0.9, 1.1, 1.3 -->8/83|
|AP 158/1||Mercedes Viano 9/03->, Vito II 9/03->|
|AP 164||LDV Maxus 2.5TD 16V (sil. VM)|
|AP 165/4||Volvo S40, V50 2/04->|
|AP 179/1||Audi A6 2.5TDI V6 7/97-> (nr części oryginalnej 059 133 843)|
|AP 186||Ford Galaxy 6/00->, Seat Alhambra 7/00->, Volkswagen Sharan 4/00->|
|AP 193||Jaguar XJ8, XK8|
|AP 193/1||Jaguar X-Type|
|AP 193/2||Jaguar XK, XK8|
|AP 193/3||Jaguar XK, XK8|
|AP 193/4||Jaguar X-Type 2.0D, 2.2D|
|AP 193/6||Jaguar S-Type|
|AP 195||Mitsubishi Colt VI, Smart Forfour|