Air Filter Frame With Brush Seal for Perimeter Blow-By
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air cleaners with hinged and latched frames experience issues such as inconsistent track fabrication leading to air leakage, protruding hinges and latches causing installation difficulties, and lack of a surface for easy removal, resulting in degraded performance and service challenges.
Innovation Solution
The air filter design incorporates a brush seal track with a brush seal, a flexible hinge, and low-profile latches integrated within the frame dimensions, along with a handle for easy removal, to address these issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frame is made rigid with traditional hinges and latches, then structural strength is improved, but sealing performance deteriorates due to blow-by around the perimeter
Solution Approach 1:
A brush seal is introduced as an intermediary element between the filter media and the track. The brush seal consists of flexible bristles that make contact with the track surface, creating a sealing interface that prevents blow-by while allowing the rigid frame structure to maintain its strength.
Solution Approach 2:
The brush seal utilizes flexible bristles (thin film-like structure) that can deform and conform to the track surface. This flexibility allows the seal to maintain contact and prevent air leakage even when the rigid frame experiences dimensional variations due to track fabrication inconsistencies.
2Reliability
If hinges and latches protrude from the frame surface, then latching function is improved, but ease of operation deteriorates due to difficulty in installation and service
Solution Approach 1:
The hinges and latches are designed to nest within recesses in the frame surface rather than protruding outward. The latch mechanism is received in a recess that positions it flush with or slightly below the frame surface, eliminating interference with track mounting screws and rivets while maintaining full latching functionality.
Solution Approach 2:
The frame surface is designed with localized recesses at specific positions to accommodate the hinges and latches. This creates areas of different surface levels: recessed areas for the hardware and flush areas for the surrounding frame, allowing the hardware to be hidden while maintaining access for operation.
3Device complexity
If the frame is undersized to accommodate protruding hardware, then device complexity is reduced, but sealing performance deteriorates due to increased blow-by
Solution Approach 1:
The brush seal serves as a mediator that compensates for the full-size frame design. Instead of reducing frame size to accommodate hardware, the brush seal is introduced as an additional sealing element that ensures tight sealing even when the frame maintains its full designed dimensions.
4Shape
If no surface is provided on the frame, then aerodynamic profile is improved, but ease of operation deteriorates due to difficulty in gripping for removal
Solution Approach 1:
The frame surface is segmented into different functional zones: smooth aerodynamic surfaces for the majority of the frame, and localized textured or protruding grip zones at strategic positions. These grip zones provide surfaces for tool engagement or hand gripping without significantly disrupting the overall aerodynamic profile.
Solution Approach 2:
The frame surface has different local qualities: smooth areas for aerodynamics and localized textured or protruding areas for gripping. The grip surfaces are positioned at edges or corners where they provide leverage for removal without affecting the main aerodynamic surfaces.
Data Source
AI summary
An air filter has a mechanism for preventing blow-by around a perimeter of the filter. The air filter has two rigid frames surrounding a filter and at least one of the rigid frames comprises a brush seal track with a brush seal therein. The air filter includes a latching mechanism to engage the rigid frames to each other and a handle for installation and removal.