One-Piece Die-Cut Panel Filter Frame Design
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Solution Overview
Problem
Existing panel air filters face challenges in manufacturing efficiency and material usage due to complex frame designs that require additional support structures and excessive material, leading to increased costs and complexity.
Innovation Solution
A simplified one-piece panel filter frame design with interlocking features, such as slits in flaps, that securely hold the frame together during assembly with minimal additional material and die changes, allowing for self-supporting pleated filter media without additional rigid materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex frame designs with multiple support structures are used, then the structural integrity of the pleated filter media is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes unnecessary support structures (scrim, intermittent wedges) from the frame design, extracting only the essential functional elements needed to maintain pleat shape while reducing overall complexity
Solution Approach 2:
The frame is divided into discrete components including side walls, end walls, and flaps that can be independently manufactured and assembled, reducing the complexity of the overall structure while maintaining structural integrity
2Strength
If multiple pieces of paperboard are folded and adhesively bonded to form the frame, then the frame provides adequate support, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
Multiple frame components (side walls, end walls, flaps) are merged into a single integrated paperboard structure that is formed in one manufacturing process, eliminating the need for separate assembly steps while maintaining structural support
Solution Approach 2:
The frame is pre-formed as a complete integrated structure during the paperboard forming process, with all necessary features (flaps, folds, interlocking elements) already in place, eliminating the need for subsequent assembly operations
3Shape
If additional rigid materials and support structures are added, then the pleated filter media maintains its shape better, but the material usage and cost increase
Solution Approach 1:
The pleated filter media is designed to be self-supporting through its own structural configuration, eliminating the need for additional rigid materials or support structures while maintaining pleat shape retention
Solution Approach 2:
The patent uses thin, flexible paperboard structures with strategic folds and flaps that provide adequate support without requiring rigid materials, reducing material usage while maintaining shape integrity
4Stability of the object's composition
If interlocking features are added to the frame, then the frame assembly stability is improved, but the device complexity increases
Solution Approach 1:
Interlocking features are integrated directly into the paperboard structure itself rather than being separate components, combining the interlocking function with the structural elements to minimize added complexity
Solution Approach 2:
The patent uses simple intermediary elements such as flaps and folds that mediate between frame components, providing interlocking and stabilization functions through basic geometric features rather than complex mechanisms
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 design enhances manufacturing efficiency, reduces material usage, and provides a cost-effective, simplified frame structure that maintains the shape and structural integrity of the pleated filter media, improving the overall production process and product performance.
Implementation Method 1
adhesively bonded pieces of paperboard
Data Source
AI summary
A panel filter frame and panel filter are provided. The panel filter frame is made from a one-piece die-cut blank of material. The die-cut blank includes a grill portion, four sidewall portions and four flap portions all integrally connected. Individual sidewall portions are interposed between a side of the grill portion and one of the four flap portions. The plurality of portions of the die-cut blank are interconnected at fold lines. The frame is formed when the die-cut blank is folded about the fold lines and the portions are secured in the folded position by at least a plurality of interlock receptacles formed in the terminating folded portion of the die-cut blank.