Collapsible V-bank Filter with Flexible Side Panels
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Solution Overview
Problem
V-bank filters are bulky and costly to ship due to the space between pleated panels, and assembling individual panels into a V-configuration is cumbersome and expensive, necessitating a collapsible design that maintains an airtight connection.
Innovation Solution
A collapsible V-bank filter with flexible thermoplastic side panels and end caps that can be thermoplastically welded or ultrasonically bonded to the pleated panels, allowing the filter to transition between operating and collapsed positions while maintaining airtight connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If V-bank filters are shipped in a fixed V-configuration, then the filter structure is stable and ready for installation, but the shipping cost increases due to large space between pleated panels
Solution Approach 1:
The filter frame is designed with flexible side panels that allow the filter to transition between a collapsed shipping configuration and an expanded operating configuration. The flexible side panels enable the filter to be compressed into a compact form for shipping while maintaining structural integrity when installed in HVAC systems.
Solution Approach 2:
The pleated filter panels are nested within the flexible side panels during shipping, allowing the filter to occupy minimal space. The flexible side panels wrap around and contain the pleated panels in a compact arrangement, enabling multiple filters to be shipped in a single carton.
2Loss of energy
If individual panels and rigid framing are used for assembly, then shipping costs are reduced, but forming an airtight connection becomes difficult and time consuming
Solution Approach 1:
The flexible side panels are thermoplastically welded or ultrasonically bonded to the pleated filter panels to form a unified, airtight structure. This merging of components eliminates the need for separate rigid framing and multiple connection points, simplifying both manufacturing and assembly while ensuring air tightness.
Solution Approach 2:
The side panels are made from thermoplastic material that changes state from solid to molten during welding, then solidifies to form a permanent bond. This parameter change enables the side panels to be joined to the filter panels through thermoplastic welding or ultrasonic bonding, creating a seamless connection.
3Adaptability or versatility
If flexible thermoplastic side panels are used, then the filter can be collapsed for shipping, but the welding process requires heat and pressure
Solution Approach 1:
The patent describes two methods for joining the thermoplastic side panels to the filter panels: thermoplastic welding and ultrasonic bonding. Ultrasonic bonding replaces the mechanical heat and pressure of traditional welding with high-frequency vibration, eliminating the need for complex welding equipment while still achieving strong, airtight connections.
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 collapsible design reduces shipping costs by allowing multiple filters to be shipped in a single carton, with significant savings in packaging materials and assembly time, while maintaining filtration efficiency and ease of installation.
Implementation Method 1
the first flexible side panel and the second flexible side panel can be thermoplastically welded or ultrasonically bonded to the pleated filter panels
Implementation Method 2
the first flexible side panel and the second flexible side panel can be thermoplastically welded or ultrasonically bonded to the pleated filter panels
Data Source
AI summary
A V-bank filter having a plurality of filter panels having a first side end opposed to a second side end, the plurality of filter panels arranged into one or more V-configurations, and a first flexible side panel joined to the first side ends and a second flexible side panel joined to the second side ends. The V-bank filter having an operating position having a distance, O, between individual filter panels measured at an open end of the one or more V-configurations when in the operating position and a collapsed position having a distance, C, between individual filter panels measured at the open end when in the collapsed position. The distance C is less than the distance O when the V-bank filter is placed into the collapsed position and the plurality of filters panels can be moved between the collapsed position and the operating position while maintaining a substantially air tight connection between the plurality of filter panels and the first flexible side panel and while maintaining a substantially air tight connection between the plurality of filter panels and the second flexible side panel.