Framed Air Filter Skip-Scored Sidewall Junction
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Solution Overview
Problem
Conventional air filters face issues with sidewall deformation and separation at junctions, particularly when cut-scored lines are used, leading to aesthetically displeasing results, and crush-scored lines can make folding more difficult and introduce creases.
Innovation Solution
A combination of cut-scoring and crush-scoring, referred to as 'skip-scoring,' is employed along the sidewall score line, where cut-scored segments are used for most of the length with short crush-scored segments to prevent deformation and creasing, while maintaining ease of folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cut-scored lines are used for sidewall junctions, then ease of folding and rapid production are achieved, but sidewall deformation and separation occur leading to poor aesthetic appearance
Solution Approach 1:
The score line is segmented into multiple types: cut-scored segments for most of the length to enable easy folding and rapid production, and crush-scored segments at specific locations to prevent deformation and maintain uniformity. This segmentation allows each type of score to perform its specialized function optimally.
Solution Approach 2:
Different qualities of scoring are applied to different locations along the score line. Cut-scoring is used in regions where ease of folding is prioritized, while crush-scoring is used in regions where deformation prevention is critical. This local differentiation resolves the contradiction between productivity and manufacturing precision.
2Manufacturing precision
If crush-scored lines are used for sidewall junctions, then sidewall deformation and creasing are prevented, but folding becomes more difficult
Solution Approach 1:
The score line is divided into cut-scored segments and crush-scored segments. The cut-scored segments provide ease of folding and rapid production, while the crush-scored segments strategically positioned at critical locations prevent deformation and creasing, thus resolving the contradiction between ease of operation and manufacturing precision.
Solution Approach 2:
Crush-scoring is applied locally at specific segments of the score line where deformation prevention is most needed, rather than applying it uniformly throughout. This localized application maintains ease of folding in non-critical areas while achieving uniformity in critical junction areas.
3Productivity
If conventional scoring methods are used, then production speed is maintained, but aesthetic appeal deteriorates due to creases and non-uniformity
Solution Approach 1:
The scoring process is segmented into cut-scoring and crush-scoring operations. Cut-scoring maintains production speed by enabling rapid folding, while crush-scoring at strategic locations prevents creases and non-uniformity, thereby preserving aesthetic appearance without significantly compromising production speed.
Solution Approach 2:
Different scoring qualities are applied to different segments of the score line. Cut-scoring is used in areas where production speed is prioritized, while crush-scoring is used in areas where aesthetic appearance is critical, thus resolving the contradiction between productivity and shape quality.
Data Source
AI summary
A framed air filter that includes air filter media and a frame with four frame portions. At least one frame portion includes an inner sidewall and an outer sidewall that meet at a sidewall junction. The sidewall junction extends along a score line that includes at least one cut-scored segment and one crush-scored segment.