Experimental Studies of PowerCore Filters and Pleated Filter Baffles

The material most commonly used to filter and clean the intake air of vehicle internal combustion engines is pleated filter paper, which in most cases is shaped in the form of a cylinder or panel. The production technology has a low cost and is not complicated. In addition to high separation efficiency and filtration performance, pleated filter media are required to have low initial pressure drop, which depends on the geometry of the bed. Much research has been conducted in this area. Dust accumulated in the filter bed causes an increase in pressure drop, which is the cause of deformation and sticking of pleats. The lack of stability of the pleats, the need to strengthen them, and the need to obtain small sizes while achieving high efficiency and accuracy of filtration of engine intake air was the reason for the development of a different design and a new technology for making filter cartridges called PowerCore. The distinctive feature of these filters is axial flow in one direction of the air stream, which avoids turbulence and thus minimizes pressure drop. This paper presents a comparative analysis of a standard PowerCore and PowerCore G2 filter bed and two cylindrical filters with a pleated filter bed made of cellulose and polyester. The conditions and methodology of experimental testing of filters with test dust are presented. During the tests, the characteristics of separation efficiency and filtration performance, as well as pressure drop as a function of the mass of dust retained on the filter of two PowerCore filters and two cylindrical filters were performed. Three specimens of test filters with the same filtration area were made from each sample of filter bed. The results showed that in each test of the filter bed, there is an initial filtration period characterized by low (96–98%) initial separation efficiency and the presence of large (d(pmax)) dust grains. As the dust loading of the bed increases, the separation efficiency and filtration performance obtain higher and higher values. The initial period of filtration ends when the conventional value (99.9%) of separation efficiency is reached. The duration of this period depends on the type of filter bed and for the PowerCore G2 filter ends for a dust loading of k(m) = 33.1 g/m(2), and for the cellulose filter for k(m) = 117.3 g/m(2). During the initial period, the air behind the PowerCore G2 filter contains grains with sizes in the range of d(pmax) = 9–16 µm. Behind the cellulose filter, dust grains are much larger, d(pmax) = 17–35 µm. The total operating time of the PowerCore G2 filter, limited by the achievement of the permittivity resistance Δp(wdop) = 3 kPa, is twice that of the other filter compositions tested.