Expandable Air Filter With Separable Support Member
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Solution Overview
Problem
Conventional air filters for HVAC systems are rigid and come in standard sizes, leading to inefficiencies in storage and selection, as well as potential misfitting issues due to deviations in actual compartment sizes, causing frustration and inefficient operation.
Innovation Solution
An expandable air filter design featuring a filter media assembly with a pleated construction and an outer frame assembly that allows manual expansion in length and width directions, enabling the air filter to match the specific size of the air filter compartment for optimal sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rigid air filters with standard sizes are used, then manufacturing and retail are simplified, but storage space is wasted and fitting accuracy to actual compartments deteriorates
Solution Approach 1:
The air filter employs a flexible frame structure that can dynamically expand from a compact initial state to a larger expanded state, allowing the same filter to adapt to different compartment sizes. This dynamic transformation enables precise fitting without requiring multiple fixed-size filters, resolving the contradiction between fitting accuracy and structural complexity.
Solution Approach 2:
The filter's physical parameters (dimensions, volume) are changed through controlled expansion. The flexible frame allows the filter to transition between different size states, enabling the same filter unit to match various compartment dimensions. This parameter change capability improves fitting accuracy while avoiding the need for multiple different filter designs.
2Adaptability or versatility
If multiple differently sized rigid air filters are displayed for purchase, then customer selection options increase, but retail shelf space requirements increase
Solution Approach 1:
A single expandable air filter design serves multiple size functions. The filter can be expanded to different dimensions to match various HVAC compartment sizes, making one product universally applicable where previously multiple different-sized filters were needed. This reduces the number of SKUs required in retail while maintaining size variety options.
Solution Approach 2:
The filter adopts a nested configuration in its initial compact state, allowing it to occupy minimal space on retail shelves. When needed, the filter expands to its full operational size. This nesting principle enables efficient storage and display of multiple size variants without proportionally increasing shelf space requirements.
3Strength
If rigid air filters are shipped and stored in their final size, then structural integrity is maintained, but transportation and storage efficiency deteriorates
Solution Approach 1:
The frame structure is designed to be dynamically configurable between compact and expanded states. During shipping and storage, the filter remains in its compact initial state, minimizing transportation volume. When installed, the filter expands to its functional size, maintaining the necessary structural integrity for sealing and support. This dynamic state change resolves the contradiction between structural strength and transportation efficiency.
Solution Approach 2:
The frame utilizes flexible materials and structures that can deform between compact and expanded configurations. This flexibility allows the filter to be compressed for efficient shipping and storage, then expanded to provide the rigid sealing surface needed for proper installation. The flexible shell maintains structural integrity throughout the transformation cycle.
Data Source
AI summary
An expandable air filter. The air filter including a filter media assembly, an outer frame assembly, and at least one support member. The filter media assembly defines opposing, first and second major faces and a perimeter. The outer frame assembly is arranged about the perimeter. The support member is connected to the outer frame assembly and extends across the first major face. Further, the support member defines a line of separation at which the support member can be separated into first and second segment to permit expansion of the air filter. The filter media can form a plurality of pleats, with at least one pleat being free of bonding to the outer frame assembly. The unbonded pleat experiences expansion as the air filter transitions to an expanded state. The air filter can be configured for expansion in one or both of a length and width direction.