Expandable Air Filter Frame for Multi-Size HVAC Compartment Fit
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Solution Overview
Problem
Conventional air filters for HVAC systems and other air handling devices are rigid, leading to sizing issues that result in inefficient use of space during transportation and retail display, and can be difficult for consumers to match correctly to their systems, causing delays in replacement and potential suboptimal operation.
Innovation Solution
An air filter device comprising an air filter unit and an expansion unit that allows for adjustable dimensions, enabling the air filter to fit variously sized compartments through expansion in length, width, or depth, either pre-assembled or as a kit for user assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional rigid air filters are used, then the filter structure is simple and manufacturing is easy, but the filter occupies large space during transportation and retail display
Solution Approach 1:
The air filter employs an expandable frame structure that transitions from a compact collapsed state during transportation to an expanded operational state during use. The frame includes movable sides that can be extended outward, allowing the filter to adapt its volume dynamically based on operational requirements rather than maintaining a fixed large size throughout the product lifecycle.
Solution Approach 2:
The expandable frame structure allows the filter media to be nested within or alongside the collapsible frame members during transportation. The frame sides can be folded inward or stacked together, creating a compact nested configuration that significantly reduces the volume occupied during shipping and retail display while maintaining full functionality when deployed.
2Adaptability or versatility
If multiple differently sized air filters are displayed, then consumers can find the correct size, but it becomes difficult for consumers to recall and select the correct size
Solution Approach 1:
The expandable air filter is designed as a universal solution that can adapt to multiple different HVAC compartment sizes. By incorporating an expandable frame that can be adjusted to various dimensions, a single filter model can serve multiple compartment configurations, eliminating the need for consumers to purchase different sized filters for different systems.
Solution Approach 2:
The filter utilizes adjustable frame parameters (length, width, depth) that can be modified to match different compartment dimensions. The expandable mechanism allows the physical parameters of the filter to be changed post-manufacturing, enabling a single product to conform to multiple size specifications rather than requiring separate products for each size.
3Productivity
If standard sized air filters are manufactured, then production is efficient, but the filters may not fit actual HVAC compartments that deviate from standard sizes
Solution Approach 1:
The filter employs a dynamic expandable frame structure that can be adjusted after manufacturing to match the specific dimensions of the target HVAC compartment. This allows a single standardized manufacturing process to produce filters that can subsequently be adapted to various field conditions, combining the benefits of efficient standardized production with the flexibility of custom fitting.
Data Source
AI summary
An air filter device including an air filter unit and an expansion unit. The air filter unit includes a filter media assembly maintained by an outer frame assembly. The outer frame assembly defines exterior length, width and depth dimensions of the air filter device in an initial state. The expansion unit provides one or more of an expanded length, width or depth in an expanded state of the air filter device. Portions or an entirety of the expansion unit can provided apart from the air filter unit in a deliver condition of the air filter device, or can be assembled to the air filter unit prior to delivery to a user. The air filter devices of the present disclosure are useful with a wide variety of differently size air handling devices, able to readily seal with an air handling device compartment via the expansion unit.