Collapsible Refillable Air Filter Frame Design
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Solution Overview
Problem
Existing air filter systems do not provide a complete solution with a combination of a reusable and collapsible frame and a disposable collapsible filter, nor can they be efficiently shipped in small containers compared to traditional systems.
Innovation Solution
A refillable air filter system comprising a reusable and collapsible frame with a disposable filter that is releasably secure within the frame, convertible between a storage/collapsed and functional/expanded configuration, featuring a design that includes a lower and upper horizontal support member with vertical support members, magnets, and angled surfaces for debris reduction, allowing for compact shipping and easy filter replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional air filter systems are used, then air filtration function is provided, but shipping container size is large and filter replacement is inconvenient
Solution Approach 1:
The air filter system is divided into two separate components: a reusable frame assembly and a disposable filter element. This segmentation allows the frame to be collapsed and reused, while only the filter element needs to be replaced, improving both shipping efficiency and user convenience.
Solution Approach 2:
The frame assembly is designed to be collapsible and expandable. It can be collapsed to a compact size for shipping and storage, then expanded to its full operational size when installed in the HVAC system, dynamically adapting between transport and use states.
2Object-affected harmful factors
If traditional air filter systems are used, then air filtration function is provided, but environmental impact is increased due to disposable nature
Solution Approach 1:
The frame assembly is designed to be recovered and reused multiple times, while only the filter element is discarded. This extends the product lifecycle and reduces waste compared to completely disposable systems, addressing environmental concerns while maintaining filtration functionality.
3Ease of operation
If a reusable frame assembly is used, then filter replacement convenience is improved, but frame structural complexity increases
Solution Approach 1:
The frame assembly is segmented into modular components including side walls, end walls, and corner pieces that can be independently manufactured and assembled. This modular segmentation simplifies the overall structure while enabling easy disassembly for filter replacement.
Solution Approach 2:
The filter element is completely extracted from the frame assembly, allowing the frame to be a simple, lightweight structure without complex retention mechanisms. The filter is removed as a complete unit, leaving the frame empty and ready for the next filter installation.
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
Enables efficient shipping in small containers and convenient filter replacement, reducing environmental impact through compostable or recyclable materials, while maintaining effective air filtration performance.
Implementation Method 1
The end walls may be magnetically closable, allowing the frame to be easily assembled and disassembled
Data Source
AI summary
A refillable air filter system, including: a reusable and collapsible frame; and a disposable filter that is releasably securable within the collapsible frame, wherein the filter is convertible between a storage/collapsed configuration and a functional/expanded configuration.