Air Filter Frame with Hollow Internal Support Channels
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Solution Overview
Problem
Conventional air filters for HVAC systems face challenges in providing adequate support while maintaining airflow, with metal-screened filters being costly and prone to deformation, and all-cardboard filters lacking rigidity.
Innovation Solution
An air filter design featuring internal support structures within the frame that form a hollow channel to provide rigidity, comprising a filter media with attached support structures and reinforcing strips, constructed from a single piece of material and attached to the frame sections to prevent air bypass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal screening is used to support the filter media, then the air filter rigidity is improved, but the cost increases and the air filter becomes prone to deformation when bent or twisted
Solution Approach 1:
The patent changes the material parameters by using cardboard with increased density and optimized geometric configuration (internal support structures) to achieve the rigidity previously only attainable with metal screening, thereby reducing cost while maintaining structural strength
Solution Approach 2:
The patent creates a composite structure combining cardboard frame sections with internal support structures formed from the same or similar material, integrating multiple functional elements (support, airflow passage, structural rigidity) into a unified composite design that eliminates metal components
2Strength
If metal screening is used to support the filter media, then the air filter rigidity is improved, but the air filter deforms when bent or twisted
Solution Approach 1:
The patent modifies the geometric parameters of the cardboard structure by introducing internal support structures with specific configurations (vertical walls, horizontal connections) that distribute mechanical stresses and prevent deformation while maintaining rigidity
Solution Approach 2:
The patent divides the frame into multiple sections with internal support structures segmented into vertical walls and horizontal connections, creating a modular framework that provides rigidity while accommodating the overall filter shape without deformation
3Ease of manufacture
If all-cardboard frames are used to reduce cost, then the manufacturing cost decreases, but the air filter lacks sufficient rigidity
Solution Approach 1:
The patent changes the structural parameters of cardboard by optimizing density, thickness, and geometric configuration of internal support structures to achieve metal-level rigidity from a low-cost material
Solution Approach 2:
The patent creates a composite cardboard structure integrating frame sections with internal support structures, forming a unified all-cardboard construction that achieves rigidity equivalent to metal-screened filters without using metal or expensive materials
4Strength
If internal support structures are added to the frame, then the structural integrity is improved, but the device complexity increases
Solution Approach 1:
The patent merges the frame structure with internal support structures into a single integrated cardboard component, eliminating the need for separate metal screens or additional support elements and simplifying manufacturing while maintaining structural integrity
Solution Approach 2:
The patent designs the cardboard frame sections to perform multiple functions simultaneously: providing structural support, creating internal hollow channels for rigidity, and serving as the primary frame structure, thereby reducing overall device complexity through multi-functionality
Data Source
AI summary
An air filter having hollow support channels in its frame is disclosed. In one embodiment, the air filter comprises a support structure having a center portion and sidewalls positioned on opposite sides of the center portion, the center portion of the support structure attached to a side of a filter media, and a frame having a plurality of sections, each of the sections having a center portion and sidewalls positioned on opposite sides of the center portion, a first frame section attached to the support structure by connecting the sidewalls of first frame section to the sidewalls of the support structure to form a hollow channel between the first support structure center portion, the frame section center portion, and the sidewalls. Methods for cutting air filter sections and for attaching a frame to the air filter sections is also disclosed.