Air Filter Frame Tab Relief for Assembly
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Solution Overview
Problem
Existing frame assembly methods for air filters require significant manual handling and labor due to the use of glue or complex slot configurations, which are inefficient and costly.
Innovation Solution
A frame design featuring a tab on one folding side portion that fits into a trapezoidal hole on an adjacent side portion, allowing for assembly without folding or manipulation, using materials like cardboard or plastic, and secured with adhesives or staples, replacing traditional slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glue or complex slot configurations are used for frame assembly, then the frame can be assembled, but the assembly process requires significant manual handling and labor
Solution Approach 1:
The frame is divided into separate side portions with tabs and slots, allowing modular assembly without requiring glue or complex handling. Each side portion can be independently assembled by inserting tabs into slots, significantly reducing manual labor and improving assembly efficiency
Solution Approach 2:
Tabs and slots serve as intermediary elements that facilitate assembly between frame side portions. The tab-slot mechanism acts as a mediator that enables easy connection without requiring glue application or complex manipulation, directly addressing the labor-intensive assembly problem
2Productivity
If tabs are used for assembly, then manual handling is reduced, but the tabs must be precisely aligned and inserted into slots
Solution Approach 1:
The tabs and slots are designed with asymmetric geometries where the tab width and slot dimensions are deliberately mismatched to provide visual and physical alignment guidance. This asymmetric design ensures that tabs can only be inserted in the correct orientation, eliminating alignment precision requirements while maintaining high assembly efficiency
Data Source
AI summary
A frame comprising a first folding side portion attached to a body and a second folding side portion attached to the body adjacent to the first folding side portion. The first folding side portion further comprises a tab adjacent to the second folding side portion. The second folding side portion further comprises a hole adjacent to the first folding side portion, wherein the tab is configured to fit into the hole without folding when the first folding side portion is arranged perpendicular to the second folding side portion and the first folding side portion and the second folding side portion are each perpendicular to the body.