Intake Mesh/Filter Research

Owned by
Kaden Nguyen
Last updated: Feb 17, 2024 by
Nitish Adaikkalam Baskar
8 min read

Factors to consider 

Stainless Steel vs Nylon vs Aluminum- 

Stainless Steel Mesh:

Pros:

    1. Durability: Stainless steel mesh is highly durable and resistant to corrosion, rust, and degradation from exposure to harsh environmental conditions.
    2. Strength: It offers excellent mechanical strength and impact resistance, providing reliable protection for air ducts against debris and physical damage.
    3. Temperature Resistance: Stainless steel can withstand high temperatures without deformation or degradation, making it suitable for automotive applications exposed to heat.
    4. Longevity: It has a long lifespan and maintains its structural integrity over time, reducing the need for frequent replacements.
    5. Easy Maintenance: Stainless steel mesh is easy to clean and maintain, requiring minimal upkeep to retain its performance characteristics.

Cons:

    1. Cost: Stainless steel mesh tends to be more expensive than alternatives like nylon mesh, making it a higher initial investment.
    2. Weight: It is heavier than nylon mesh, which may be a consideration in weight-sensitive automotive designs.
    3. Rigidity: Stainless steel mesh is less flexible compared to nylon, which may limit its suitability for applications requiring flexibility or contouring.

Price: Stainless steel mesh typically ranges from $5 to $20 per square foot, depending on factors such as mesh size, thickness, and grade of stainless steel.

Nylon Mesh:

Pros:

    1. Lightweight: Nylon mesh is lightweight and flexible, making it suitable for applications where weight reduction is important, such as in lightweight vehicles or where flexibility is required.
    2. Corrosion Resistance: Nylon is resistant to corrosion, which can be beneficial in environments with exposure to moisture or chemicals.
    3. Cost: Nylon mesh is generally more affordable than stainless steel mesh, providing a cost-effective option for budget-conscious projects.
    4. Flexibility: Nylon mesh can be easily molded or shaped to fit various contours, allowing for greater design flexibility in complex automotive cooling systems.
    5. Ease of Installation: It is relatively easy to install and work with compared to stainless steel mesh, requiring less specialized equipment or expertise.

Cons:

    1. Durability: Nylon mesh is less durable than stainless steel and may degrade over time, especially under prolonged exposure to UV radiation or high temperatures.
    2. Strength: It has lower mechanical strength and impact resistance compared to stainless steel, potentially offering less effective protection against debris or physical damage.
    3. Temperature Limitations: Nylon mesh has a lower temperature resistance compared to stainless steel and may deform or melt at high temperatures, limiting its suitability for certain automotive applications.

Price: Nylon mesh typically ranges from $1 to $5 per square foot, depending on factors such as mesh size, thickness, and weave pattern.

In summary, while stainless steel mesh offers superior durability, strength, and temperature resistance, it comes at a higher cost and heavier weight. On the other hand, nylon mesh provides cost-effective lightweight options with greater flexibility but may lack the same level of durability and temperature resistance as stainless steel. The choice between the two depends on the specific requirements and priorities of the automotive cooling system, balancing factors such as performance, budget, and environmental conditions. 

Aluminum Mesh:

Pros:

          a. Weight: a more lightweight metal compared to steel or stainless steel

          b. Rust: corrosion resistant (aluminum oxide) so suitable for more harsh conditions

          c. Cost: cheaper metal material, much more affordable

          d. One of the more popular car grille meshes, has been proven to be a solid option

Cons:

          a. Properties: aluminum is a good conductor, so not ideal to place close to battery box

          b. Durability: stronger compared to nylon, but one of the more weaker metal options. Prone to damage like dents and bends

          c.  Temperature Limitations: Good heat protection, yet not as good as stainless steel 


Mesh to Buy (STAINLESS STEEL HIGH MESH DENSITY FOR BEFORE INTAKE):

https://www.amazon.com/AggAuto-Stainless-Automobile-Protection-Automotive/dp/B0CC2JJPZ4/ref=sr_1_3?crid=3L0I6IJBBYIVH&keywords=mesh%2Bfor%2Bcar%2Bgrill%2Bstainless%2Bsteel&qid=1707589341&sprefix=mesh%2Bfor%2Bcar%2Bgrill%2Bstainless%2Bsteel%2Caps%2C236&sr=8-3&th=1

Mesh to Buy (ALUMNIMUM LOWER MESH DENSITY FOR FRONT OF CAR):

https://www.amazon.com/AggAuto-Stainless-Automobile-Protection-Automotive/dp/B08QRPP8VB/ref=sr_1_3?crid=3L0I6IJBBYIVH&keywords=mesh%2Bfor%2Bcar%2Bgrill%2Bstainless%2Bsteel&qid=1707589341&sprefix=mesh%2Bfor%2Bcar%2Bgrill%2Bstainless%2Bsteel%2Caps%2C236&sr=8-3&th=1



Stainless Steel 

Pros: has chromium (shields from oxidization), longevity, great for outdoor use, wide-range for aperture, strong chemical resistance, extremely durable, strong heat resistance 

Cons: more costly than a plastic/cheaper material mesh, heavier weight, susceptible to bending from external forces

Nylon

Pros: resistant to bending or stretching as it is flexible, good for aesthetic uses, absorbs water, versatile material, cost effective, lightweight but still relatively strong, easy maintanence, heat resistant 

Cons: typically acid dyed (issues with bleaching and fading), poor resistance to sunlight (causes it to weaken), low burn and melting point



  1. Material Selection:
    1. Choose a material for the mesh that is durable, heat-resistant, and able to withstand environmental conditions. Stainless steel or other corrosion-resistant materials are commonly used for this purpose.
    2. Different types of materials: 

      1. Stainless Steel Mesh:

        • Stainless steel meshes are durable, corrosion-resistant, and often used in automotive applications. They are available in various weave patterns and can effectively filter out debris.

      2. Aluminum Mesh:

        • Aluminum meshes are lightweight and corrosion-resistant. They are suitable for applications where weight is a concern and can offer good protection against larger particles.

      3. Plastic Mesh:

        • Some cars use plastic mesh, especially in areas where weight is a critical factor. These meshes are lightweight, corrosion-resistant, and can be molded into various shapes.

      4. Expanded Metal Mesh:

        • Expanded metal meshes are made by cutting and stretching a metal sheet, creating a pattern of openings. They are known for their strength and can be customized for different applications.

      5. Hexagonal Mesh:

        • Hexagonal mesh, also known as hex mesh or honeycomb mesh, is characterized by hexagonal openings. This type of mesh is often used in grille designs and can be aesthetically pleasing while providing protection.

      6. Nylon Mesh:

        • Nylon meshes are lightweight and can be suitable for filtering larger particles. They are also resistant to corrosion and can be a cost-effective option.

      7. Wire Mesh with Epoxy Coating:

        • Wire meshes with epoxy coatings provide an additional layer of protection against corrosion. The epoxy coating can enhance the durability of the mesh in harsh environmental conditions.

      8. Powder-Coated Mesh:

        • Meshes with powder coatings offer protection against corrosion and can be customized in terms of color. This type of coating adds an extra layer of durability.
  2. Mesh Density:
    1.  Determine the appropriate mesh density based on the size of particles you want to filter out. The finer mesh will provide better protection against smaller particles but may also impede airflow, so finding a balance is crucial.
    2. Types of mesh densities: 

      1. Low Mesh Density (Coarse Mesh):

        • Function: Allows larger particles to pass through while restricting smaller ones.
        • Application: Used in situations where maintaining high airflow is crucial, and the primary concern is preventing larger debris from entering. Example: Grilles in front of radiators.

      2. Medium Mesh Density:

        • Function: Balances between airflow and particle filtration.
        • Application: Suitable for general-purpose filtration where a compromise between airflow and protection against various particle sizes is necessary. Examples: Air intake filters, and some radiator grilles.

      3. High Mesh Density (Fine Mesh):

        • Function: Provides high filtration efficiency by restricting both large and small particles.
        • Application: Used in environments where finer filtration is required, such as protecting sensitive components or systems from smaller particles. Example: Air intake for electronic components, protecting heat exchangers.

      4. Ultra-High Mesh Density (Very Fine Mesh):

        • Function: Offers superior filtration for extremely small particles.
        • Application: Critical applications where even tiny particles could cause damage. Examples include protecting delicate sensors or components in high-tech applications.

      5. Variable Mesh Density (Gradient Mesh):

        • Function: Gradually changes density across the surface.
        • Application: Used to optimize filtration efficiency by having a finer mesh where higher protection is needed and a coarser mesh in areas where airflow is a priority. Example: Air filters with variable density.

      6. Hexagonal or Honeycomb Mesh:

        • Function: Offers a unique pattern with open areas and structural stability.
        • Application: Commonly used in grille designs, providing a balance between protection and aesthetics. 
  3. Airflow Considerations:
    1. Ensure that the chosen mesh does not significantly impede the airflow needed for the cooling system. Conduct tests or simulations to evaluate the impact of the mesh on the airflow to guarantee efficient cooling. (We haven't done any tests on this soo....) 
  4. Structure:
    1.  Consider the shape and structure of the mesh. Flat, perforated sheets or 3D-shaped meshes are common options. The design should facilitate easy airflow while providing effective particle filtration.
    2.  The Inner intake will have one mesh, and the other mesh will be attached to the intake of the battery box. The diameter of the intakes is 4in. 
  5. Mounting and Sealing:
    1. Ensure proper mounting of the mesh to the intake area, and create a tight seal to prevent bypassing of particles. This also helps in directing the airflow through the mesh.
  6. Water Resistance:
    1. Depending on the car's usage environment, consider making the mesh water-resistant to prevent water ingress during wet conditions.
  7. Regulatory Compliance:
    1. Check if there are any regulatory standards or guidelines related to cooling system intakes for electric vehicles or cars in general. Ensure that your design complies with these standards. 
      1. ASC2023 Regs: The regulations don't mention a mesh so we chillinnnnn 

Factors that need to be considered because of location - Bowling Green - Kentucky 

  1. Climate:

    • If the car will operate in dusty or sandy environments, such as deserts or construction sites, a finer mesh may be necessary to prevent small particles from entering the cooling ducts. 
    • For us 

  2. Terrain:

    • Consider the type of terrain the car will traverse. Off-road conditions may expose the intake to more debris, requiring a robust and effective mesh design. Urban driving may have its own set of challenges with pollution and particulate matter.

  3. Altitude:

    • Operating at higher altitudes may affect the performance of the cooling system. Ensure that the mesh design takes into account any changes in air density and temperature that may occur at different altitudes.

  4. Rain and Water Management:

    • If the car is expected to encounter heavy rain or water splashes, design the mesh to handle water effectively. It should prevent water ingress while still allowing proper airflow. Consider integrating water drainage channels if needed.

      The current mesh we are planning to buy:        
  5. https://www.amazon.com/AggAuto-Universal-Grill-Mesh-Multifunctional/dp/B08PBM1C2F/ref=sr_1_5?keywords=Mesh%2Bfor%2BCar%2BGrill&qid=1686425883&sr=8-5&th=1 
  6. 12mm x 6 mm rhombic holes 

 

Water-resistant mesh or coating? 

  •  

 

Dust resistant mesh:  

^possible, but I am not sure if it is good though

Ways to attach mesh to intake of vehicle:

  • Usage of adhesive 
    • Automotive Goop: type of adhesive used typically for plastic or metal mesh that is used for car grilles. Relatively cheap adhesive and takes 1 full day to properly cure. Need to make sure mesh is flush on intake when installing (can be easily done with zip ties and other materials to keep the mesh in place). Strong adhesive that should stay durable. Keep in mind this would keep the mesh in place on the intake so necessary maintenance might be tricky. Also need to consider if we want to use the adhesive on the inner or outer part of the intake. 
      • usage of a 3-D printed double ring (or some other material) to put the flushed mesh into a place where the adhesive does not impact airflow (when placed on the inside of the intake) or be fully exposed to the open air (when placed on the outside of the intake


  • Usage of Tape
    • Foam Tape: provides an air-tight acrylic adhesive seal and is adjustable/flexible. Relatively strong (not as strong as if using a glue adhesive, made of polyethylene foam) but also allows for easier maintenance if necessary. Probably most ideal to put on the outer part of the intake so that the tape and overlaying mesh do not interfere with the airflow going through the intake. High-density material and can handle both heat and cold pretty well (-60 to 150 Fahrenheit). 


  • Usage of Metal Frame
    • Using bending metal frames to wrap around the intake and have the mesh sandwich in between. Drill screws through the metal frames to keep the mesh in place. If done this way, need to be aware of screw size and strength to make sure mesh is secured properly and also make sure screws do not interfere with airflow within the intake passage. Relatively easy to maintain because screws can be removed, however not as strong as using a glue adhesive. 


  • Usage of Cap System
    • Adding a cap on top of an already flushed mesh would allow for strong security and also easy maintenance. The cap would attach to latches of a rim added to the front of the intake. This would most likely be designed and produced in-house (most likely 3-D print material). Also thinking of maybe using a silicon type material that would sandwich the cap edges within the inside of the rim. 

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