Air Filter Frame Segmentation for Round Channel Integration
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Solution Overview
Problem
Existing air filter manufacturing methods are inefficient for producing filters with round cross-sections, leading to increased material loss and difficulty in automation, especially when trying to mount filters in round channels or passages.
Innovation Solution
A method involving a four-sided filter frame made of elongated distance elements, which is cut to form a circular shape, allowing for reduced material loss and efficient production, using a punching tool to create a round filter frame with equally divided flexible fibers, and a snap-in connection or attachment mechanism for secure placement within a tubular casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a round filter frame is manufactured by rolling up flexible band with distance elements, then the filter can be mounted in round channels, but the flow resistance increases in the centre area and manufacturing automation becomes difficult
Solution Approach 1:
The filter frame is segmented into multiple straight distance elements arranged side by side to form a rectangular frame, which is then cut into a circular shape. This segmentation allows each distance element to be manufactured separately using standardized processes, enabling automation while achieving circular mounting compatibility.
Solution Approach 2:
Instead of forming a round filter frame by rolling up a flexible band (as in prior art), the invention inverts the approach by assembling straight distance elements into a rectangular frame and then cutting it into a circular shape. This reversal of the manufacturing sequence eliminates the need for complex rolling operations and enables automated production.
2Ease of manufacture
If a four-sided filter frame with rectangular distance elements is used, then manufacturing is simplified and automation is easier, but the filter cannot be mounted in round channels or passages
Solution Approach 1:
The filter frame is preliminarily assembled as a rectangular configuration using straight distance elements, which simplifies manufacturing and enables automation. The circular shape is then achieved in a subsequent cutting step, thereby preliminarily establishing the manufactured form before final adaptation to round channels.
Solution Approach 2:
The filter frame is divided into multiple straight distance elements that can be manufactured using standardized automated processes. These segmented elements are then assembled into a rectangular frame and cut into a circular shape, combining manufacturing simplicity with mounting versatility.
3Shape
If the flexible fibres are rolled up with increasing number per area unit towards the centre, then the round filter frame shape is achieved, but the flow resistance becomes non-uniform with larger resistance in the centre area
Solution Approach 1:
The distance elements are equipped with uniformly distributed attachment points along their entire length, ensuring that flexible fibres are attached with consistent spacing and density across all locations. This local uniformity in attachment quality compensates for the circular shape, maintaining uniform flow resistance throughout the filter frame.
Solution Approach 2:
The filter frame is constructed with homogeneous distribution of distance elements and attachment points, ensuring uniform flexible fibre spacing across the entire circular perimeter. This homogeneous structure eliminates the non-uniform fibre density that would otherwise occur in rolled-up constructions, achieving both circular shape and uniform flow resistance.
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
Enables the production of air filters with reduced material waste and improved manufacturing efficiency, allowing for seamless integration into round channels while maintaining uniform fiber distribution and effective air filtration.
Implementation Method 1
The filter frame is cut such that a filter frame with a substantially circular contour shape is obtained
Implementation Method 2
a filter body with a plurality of curtains of electrostatically chargeable fibres which separate particles from the air both by means of mechanical and electrostatic action
Implementation Method 3
separate particles from the air both by means of mechanical and electrostatic action
Implementation Method 4
a snap-in connection or attachment mechanism for secure placement within a tubular casing
Data Source
Figure 1~2
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Figure 6~7
AI summary
The present invention relates to an air filter and a method for manu¬ facturing of such filter. The air filter comprises a filter frame (20) which comprises a plurality of side by side mounted elongated dis¬ tance elements (11 ) which form passages for air, and a filter body, which comprises electrically chargeable fibres which are attached to distance elements (11 ) such that the fibres obtain an extension from the filter body (20) to a position located at a distance from and downstream the filter body (20) with respect to the intended flow direction of the air through the air filter. The filter frame (20) has a substantially round contour shape in that two peripheral and diamet¬ rically opposite distance elements (11 ) are shorter than the remain¬ ing distance elements (11 ) and that the side by side mounted dis- tance elements (11 ) have a length which increases successively in direction towards the centre of the filter frame (20).