Upstream Bridging Filaments for Pleated Air Filter Stability
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Solution Overview
Problem
Framed pleated air filters without downstream support are unable to withstand the forces encountered in typical residential HVAC systems, leading to deformation or collapse, as they are non-self-supporting and require a support frame for stability.
Innovation Solution
Incorporating bridging filaments bonded to upstream pleat tips on the upstream face of the pleated air filter media, which stabilize the pleats and prevent deformation, while maintaining the filter's non-self-supporting nature and allowing for nesting and compressibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If downstream support members are added to framed pleated air filters, then structural stability and ability to withstand HVAC forces are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention removes the downstream support member from the filter structure, extracting the problematic element that added complexity and cost. Instead of adding support on the downstream side, the patent uses upstream bridging filaments to achieve stability without the need for downstream support structures.
Solution Approach 2:
Conventional filters place support members on the downstream side to prevent collapse. This invention inverts the approach by placing bridging filaments on the upstream side, opposite to the traditional location, to achieve the same stabilizing effect without downstream support.
2Stability of the object's composition
If downstream support members are added to provide structural stability, then filter media stability is improved, but manufacturing cost and packaging efficiency worsen
Solution Approach 1:
The bridging filaments are simple, inexpensive components that can be easily manufactured and integrated. They provide adequate stability for the filter media without requiring expensive support structures, making the overall filter more cost-effective to manufacture.
Solution Approach 2:
The bridging filaments function as thin, flexible structural elements that provide necessary support while maintaining the overall flexibility and compressibility of the filter media, allowing for easier manufacturing and nesting.
3Strength
If downstream support members are added to prevent deformation, then structural integrity is improved, but nesting capability and compressibility worsen
Solution Approach 1:
The bridging filaments are flexible elements that allow the filter media to compress and deform during nesting operations, then return to their original configuration. This flexibility enables nesting capability while maintaining structural integrity during normal operation.
Solution Approach 2:
The support structure transitions from a rigid downstream support member to dynamic, flexible bridging filaments that can adapt their configuration during nesting and return to their original state, enabling both structural integrity and nesting capability.
Data Source
AI summary
A framed pleated air filter, including a non-self-supporting, compressible, pleated air filter media with a plurality of oppositely-facing pleats and with a plurality of upstream pleat tips and downstream pleat tips, the pleated air filter media further including a plurality of bridging filaments that are bonded to at least some of the upstream pleat tips. The framed pleated air filter does not include any support member on the downstream face of the pleated air filter media.