Vehicle Cabin Air Filter With Cuttable Foam for Universal Fit
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Solution Overview
Problem
Conventional cabin air filters for vehicles are inefficient in removing airborne molecular contaminants and volatile organic compounds due to their low Minimum Efficiency Reporting Value (MERV) and require multiple sizes to fit various receptacles, leading to inventory challenges and improper fitting issues.
Innovation Solution
A filter made of open cell foam material with a rectangular configuration and laser-cut cubical members that can be easily adapted to fit different sizes by separating and recombining the cubical members, providing a high MERV value of 11 without the need for tools or frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pleated-paper filters are used, then they can be easily manufactured and installed, but they have low MERV value and allow airborne molecular contaminants and VOCs to enter vehicle passenger compartments
Solution Approach 1:
The patent uses a porous foam filter medium instead of conventional pleated-paper filters. The foam material provides high MERV value (comparable to HEPA filters) by capturing airborne molecular contaminants and VOCs through its porous structure, while maintaining ease of installation and a simple rectangular frame design.
Solution Approach 2:
The patent employs composite construction combining a foam filter medium with a rectangular frame structure. This composite approach achieves both high filtration efficiency (MERV 11 or higher) and structural simplicity, resolving the contradiction between filtration performance and device complexity.
2Adaptability or versatility
If multiple sizes of filters are maintained in stock to fit various receptacles, then proper fitting is ensured, but inventory problems and complexity increase for suppliers
Solution Approach 1:
The patent designs a universal rectangular frame structure that can accommodate different receptacle sizes. The simple rectangular geometry allows the same basic filter design to be adapted to various vehicle HVAC systems, eliminating the need for suppliers to maintain multiple specialized sizes in inventory.
Solution Approach 2:
The filter is designed as a modular rectangular frame that can be segmented or adjusted to fit different receptacle dimensions. This segmentation approach allows a single base design to serve multiple size requirements, reducing inventory complexity while maintaining adaptability.
3Ease of manufacture
If improper-sized filters are provided to vehicle owners, then inventory management is simplified, but air leakage occurs and filtering effectiveness is reduced
Solution Approach 1:
The patent uses a standardized rectangular frame design with adjustable parameters (dimensions, frame thickness) that can be modified to ensure proper fit in various receptacles. This parameter adjustment capability maintains filtration effectiveness while keeping manufacturing simple through a consistent basic design.
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
The solution offers superior filtration efficiency, reduced inventory needs, easy installation, and adaptability to various filter receptacle sizes, while maintaining airflow and reducing the strain on HVAC systems, with a MERV value comparable to HEPA filters.
Implementation Method 1
The body is formed of an open cell foam material... providing a high MERV value of 11
Implementation Method 2
The body is formed of an open cell foam material... laser-cut cubical members that can be easily adapted
Data Source
AI summary
A filter for an air conditioner has a body formed of an air-transmissive material. The body is of a generally rectangular configuration and has a top, bottom, a front, a back and a pair of sides. The body has a plurality of cuts formed through a thickness thereof. The plurality of cuts define a plurality of cubical members frangibly connected together. The plurality of cubical members are separable from a remainder of the body such that the body has a size suitable for being received within a filter-receiving receptacle of the air conditioner.