Collapsible Disposable Filter Frame With Scored Center
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Solution Overview
Problem
Conventional disposable HVAC air filters are bulky, leading to increased shipping costs and storage space requirements due to their integrally connected filter media and frame, which are not easily collapsible and require frequent replacement.
Innovation Solution
A disposable collapsible air filter frame with a scored center allowing for folding and reduced thickness, enabling thinner media usage and compact storage, and a new score line design that allows the frame to collapse and expand while maintaining structural integrity, reducing shipping costs and storage space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional disposable air filters use integrally connected filter media and frame, then the filter structure is simple and easy to manufacture, but the filter occupies large storage space and increases shipping costs
Solution Approach 1:
The frame is divided into multiple longitudinal members that can be independently folded along score lines. Each longitudinal member includes a first portion and a second portion that can be positioned at different angles relative to each other, allowing the frame to transition from an expanded operational configuration to a collapsed storage configuration. This segmentation enables the filter to maintain structural integrity while significantly reducing storage volume.
2Reliability
If conventional disposable air filters are designed with standard thickness, then the filter media provides adequate filtration, but the filter requires large storage space and frequent replacement
Solution Approach 1:
The frame incorporates score lines that allow the longitudinal members to be folded and positioned at different angles. This dynamic structure enables the filter to be collapsed into a compact form for storage and transportation, then expanded to its full operational thickness when installed. The dynamic folding mechanism allows thinner filter media to provide adequate filtration while reducing storage space requirements and extending replacement intervals.
3Strength
If disposable air filters are made bulky for structural support, then the frame maintains structural integrity, but shipping costs and storage requirements increase significantly
Solution Approach 1:
The collapsible frame allows the filter to be nested into a compact configuration during storage and transportation. The longitudinal members fold along score lines to create a space-efficient nested structure that maintains structural integrity when expanded for use. This nesting capability significantly reduces the volume occupied during shipping and storage while preserving the frame's strength and support capabilities during operational use.
Data Source
AI summary
The addition of a medial longitudinal score line (hinge point) along the longitudinal channels of the filter frame allows for thinner media and/or collapsing the frame on itself which will reduce scrap, save space and save tremendously on shipping costs. The additional score line can be a cut score, skip score, crush score or liquid line. The collapsed filter frame expands upon sliding into the channels of the filter frame media holder whereby the filter frame expands and widens to fit the filter assembly.