Method of forming a custom air filter
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Solution Overview
Problem
Existing methods for producing custom air filters with non-standard sizes are costly and result in poorly constructed end products, as they are often derived from modifying standard size air filters, which is time-consuming and inefficient.
Innovation Solution
A method involving the use of support material with a pressure-sensitive adhesive (PSA) to modify standard air filters by cutting and securing replacement frame members to form custom-sized air filters, ensuring a secure seal and efficient air filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If custom air filters are produced by modifying standard size air filters, then production costs are reduced, but construction quality deteriorates and time consumption increases
Solution Approach 1:
The air filter is divided into modular components: a standard filter assembly and separate replacement frame members. The frame members can be independently manufactured and attached, allowing customization without compromising the quality of the filter media itself. This segmentation enables cost-effective production while maintaining construction quality through standardized manufacturing of individual components.
Solution Approach 2:
Replacement frame members are pre-formed with adhesive layers and scoring lines during manufacturing. The scoring lines are pre-created to facilitate accurate folding and assembly. This preliminary preparation eliminates time-consuming manual construction steps and ensures consistent, high-quality assembly when the custom filters are produced.
2Ease of manufacture
If conventional methods are used to modify standard air filters, then production time increases, but cost reduction is achieved
Solution Approach 1:
The replacement frame members are pre-manufactured with adhesive layers already applied and scoring lines pre-formed. This preliminary preparation allows for rapid assembly by simply folding along the score lines and attaching to the filter assembly, dramatically reducing production time compared to conventional manual modification methods while maintaining cost-effectiveness.
Solution Approach 2:
The replacement frame members are designed as disposable components that are easily attached and discarded with the filter assembly. This approach eliminates the need for complex, time-consuming permanent modifications and allows for quick replacement and production cycles, improving productivity without sacrificing cost benefits.
3Productivity
If standard size air filters are used, then production efficiency is high, but adaptability to unique HVAC installations is limited
Solution Approach 1:
The air filter system is segmented into a standard filter assembly and customizable replacement frame members. The frame members can be manufactured in various sizes to match unique HVAC installations, while the filter assembly itself remains standardized for efficient production. This segmentation maintains production efficiency while providing the needed adaptability.
Solution Approach 2:
The replacement frame members serve multiple functions: they provide structural support, create custom dimensions, and enable adaptation to various HVAC installations. The same basic frame member design can be scaled to different sizes while maintaining the same attachment mechanism, providing universality across different application requirements.
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 method allows for the cost-effective production of custom-sized air filters with improved construction quality, providing a secure seal that prevents air bypass and enhances filtration efficiency.
Implementation Method 1
support material with a pressure-sensitive adhesive (PSA) to modify standard air filters
Data Source
AI summary
A method of forming a custom air filter is disclosed. In accordance with the method, a first air filter having a first size is provided. A length of support material is also provided and includes a substrate covered with a pressure sensitive adhesive, over which a release layer is disposed. At least a first portion of the first air filter is cut and removed to form a nascent air filter. The length of support material is manipulated to have a channel configuration, and the release layer is removed to expose the pressure sensitive adhesive of the length of support material. The length of support material with the channel configuration is pressed into engagement with the nascent air filter such that the exposed pressure sensitive adhesive bonds to the nascent air filter, thereby forming the custom air filter.