Air Filter Corner Sealing Using Buffer Material to Prevent Leaks
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Solution Overview
Problem
Existing air filters face challenges in preventing air leaks at the corner parts of the filter frame, despite effective prevention of leaks on the side surfaces.
Innovation Solution
The air filter design incorporates a pleated filter material with zig-zag folds, a filter frame with overlapping frame materials, a buffer material between the filter frame and pleated filter material, and a seal material with controlled thermal expansion properties to prevent leaks at the corner parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the filter frame uses overlapping frame materials, then structural strength is improved, but gaps may form at corner parts
Solution Approach 1:
The buffer material serves as a mediator between the overlapping frame materials and the pleated filter material at the corner parts. It fills potential gaps created by the overlapping structure while maintaining the structural strength benefits of the overlapping design, thus resolving the contradiction between strength and sealability.
Solution Approach 2:
The overlapping frame material structure provides general structural strength throughout the filter frame, while the buffer material provides localized sealing quality specifically at the corner parts. This combination allows the structure to have different properties in different locations, resolving the contradiction between overall strength and local sealability.
2Reliability
If buffer material is added between the filter frame and pleated filter material, then corner sealability is improved, but device complexity increases
Solution Approach 1:
The buffer material performs multiple functions simultaneously: it seals corner gaps, compensates for dimensional changes due to thermal expansion, and provides a cushioning effect. This multi-functionality justifies the addition of the component by delivering multiple benefits from a single element, thereby improving corner sealability without proportionally increasing device complexity.
Solution Approach 2:
The buffer material accommodates parameter changes (thermal expansion and contraction) of the filter frame and pleated filter material. By being positioned at the corner parts, it dynamically adapts to dimensional changes, maintaining sealability under varying temperature conditions without requiring complex adjustment mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively prevents air leaks at the corner parts of the filter frame, maintaining high trapping efficiency and durability even under temperature changes, reducing the risk of dust emission and enhancing sealability.
Implementation Method 1
a seal material with controlled thermal expansion properties to prevent leaks at the corner parts
Data Source
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AI summary
To provide an air filter that is capable of preventing air leak occurring at the corner part of the filter frame. The air filter includes : a pleated filter material 20 folded into a zig-zag form at folding lines along a first direction to have peak parts and valley parts arising alternately in a second direction perpendicular to the first direction, trapping fine particles in a gaseous matter flowing in a gas flow direction perpendicular to the first direction and the second direction; a filter frame 10 being a rectangular filter frame including one pair of first frame materials 11 facing each other in the second direction having end parts in the first direction, and one pair of second frame materials 12 facing each other in the first direction having end parts in the second direction, opening in the gas flow direction and housing the pleated filter material 20, each of the first frame materials 11 and each of the second frame materials 12 being combined to provide an overlap part 15 where each of the end parts of each of the first frame materials 11 and each of the end parts of each of the second frame materials 12 overlap each other; and a buffer material 60 disposed between at least each of the second frame materials 12 of the filter frame 10 and the pleated filter material 20, held with the overlap part 15.