New air filter modules for EURO VI
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Air filter module
High filter performance and low installation space requirements characterize the new air filter module from MAHLE.
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Air filter element
New plasticized filter inserts limit installation depth to less than 15 cm.
Hanover, September 2012 – New requirements from commercial vehicle manufacturers have placed the focus in air filter development not only on compliance with maintenance intervals, but additionally on achieving high separation levels. The available installation space has also become a more significant factor. The new air filter module from MAHLE is impressive not only in these areas, but the development of market- and customer-specific overall concepts is also one of its strengths.
There are two significant trends in commercial vehicles that will greatly affect future concepts of air management. SCR systems increasingly supersede air intake from its established installation location. This means that new package solutions are required. If a low-profile design can be produced, such as the new MAHLE concept, then the air filter module can be located behind the driver's cab, although the platforms are becoming ever longer and the area between the superstructure and the cabin is thus becoming ever tighter.
When Euro VI takes effect in 2013, air mass flow measurement will be implemented in modern commercial vehicle engines as well. In order to ensure proper functionality of the air mass sensors—which are at risk from excessive particle loading—even throughout the service life of the commercial vehicles, the engine manufacturers expect air filter modules with significantly increased separation levels of greater than 99.95 percent.
In response to these trends, MAHLE has developed air filter modules with two new significant features.
Low-profile plasticized filter inserts
The first feature consists in large plasticized filter inserts that allow a flexible and low-profile design (installation depth less than 15 cm, including housing). This concept provides maximum freedom of design and can be applied to inflow and outflow in any direction, even in tight installation spaces.
Filter media with nanofiber layer
The second feature is a new filter media concept. For the first time, MAHLE is using nanofibers and polyamide fibers respectively with diameters of 90 to 110 nm. The nanofibers are applied to a thin, open-celled cellulose medium in an electrical spinning process.
The underlying concept is surface filtration. The extremely fine fabric of the nanofibers filters at a very high efficiency, storing the dust in a dust cake outside of the medium on the untreated side. The medium, which is very thin in design with a fine fiber overlay, allows very tight pleat distribution and thus sufficient filter surface area in the plasticized inserts.
Overall concept for specific markets and customers
With the new air filter module, MAHLE has developed an in-house concept that builds on expertise in the area of plastification. Of course, MAHLE also offers market-specific concepts to address the challenges of dust-laden countries, extreme conditions of use, or increased exposure to water. Precleaners in the form of individual axial cyclones or multicyclone systems are often designed to meet individual customer requests and are integrated in the air filter module. The result is a customized overall concept with a high level of filtration performance for every application.
The MAHLE Group is one of the 30 largest companies in the automotive supply industry worldwide. With its two business units Engine Systems and Components and Filtration and Engine Peripherals, MAHLE ranks among the top three systems suppliers worldwide for piston systems, cylinder components, as well as valve train, air management, and liquid management systems. MAHLE’s industrial activities are combined in the Industry business unit. These include the areas of large engines, industrial filtration, as well as cooling and air conditioning systems. The Aftermarket business unit serves the independent spare parts market with MAHLE products in OE quality. In 2011, the MAHLE Group generated sales of approximately EUR 6 billion; around 49,000 employees work at over 100 production plants and eight research and development centers.
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