Collapsible Air Filter with Self-Retaining Pleated Media
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Solution Overview
Problem
Conventional HVAC air filters are bulky, leading to unnecessary waste and cost due to the entire frame being discarded when only the filter media becomes dirty, and they occupy significant space during transportation and storage.
Innovation Solution
An expandable air filter design that transitions from a collapsed state to an expanded state for use, eliminating the need for a rigid frame and allowing self-retention in the expanded state, using a pleated filter media assembly and shape retention structures to maintain the filter's shape and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid frame is used to support the filter media and define the filter's size and shape, then the filter maintains its structural integrity and proper dimensions during use, but the entire frame must be discarded when the filter media becomes dirty, leading to unnecessary waste and cost
Solution Approach 1:
The patent removes the rigid frame entirely from the filter design. Instead of using a traditional framed structure, the filter media is folded into a compact configuration that self-supports during use. This extraction of the frame eliminates the waste problem while maintaining structural integrity through the folded geometry of the media itself.
Solution Approach 2:
The filter transitions from a static, rigid framed structure to a dynamic folded configuration. The media is folded along crease lines to create a three-dimensional structure that can be compressed for storage and then expanded for use, replacing the need for a rigid frame with a flexible folded geometry.
2Manufacturing precision
If a rigid frame is used to define the perimeter size and shape of the HVAC air filter, then the filter maintains its proper dimensions for installation, but the filter occupies a large volume during transportation and storage
Solution Approach 1:
The filter media is folded into a compact nested configuration that fits within a small shipping box. The multiple folds create a nested structure where the large surface area of the filter media is condensed into a small volume, similar to how a nested doll contains smaller dolls within larger ones. This allows the filter to be shipped and stored in a fraction of the space it would occupy with a rigid frame.
Solution Approach 2:
The filter structure is dynamic rather than static, allowing it to transition between a compact folded state for storage and transport, and an expanded state for use. The folded media maintains its dimensional integrity when installed in the HVAC system while occupying minimal space during logistics and storage.
3Reliability
If the entire air filter is replaced when the filter media becomes dirty or clogged, then the filter function is restored, but the frame and other reinforcing components are discarded even though they remain functional, leading to unnecessary waste and cost
Solution Approach 1:
By removing the rigid frame and reinforcing components entirely, the patent eliminates the problem of discarding functional parts. The filter media alone, folded into a compact configuration, becomes the complete filter assembly. When the media becomes dirty, the entire folded structure is replaced, but no additional frame or supporting components need to be discarded since they don't exist as separate elements.
Data Source
AI summary
The present disclosure generally relates to air filters expandable from a collapsed arrangement to an expanded, end-use arrangement and to methods of making, using, and installing such air filters. Some embodiments relate to an air filter having an expanded state and a collapsed state. The air filter includes a filter media assembly including (1) filter media including a plurality of pleats, (2) first and second opposing sides, and (3) first and second opposing ends. The air filter also includes a shape retention structure capable of being connected to at least a portion of the filter media assembly and capable of retention the filter media assembly in the expanded state. A spacing distance between adjacent pleats in the filter media is greater in the expanded state of the air filter than in the collapsed state of the air filter. In some embodiments, the air filter is an HVAC air filter.