Filter assembly and air cleaner including the same
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Solution Overview
Problem
Existing air cleaners face challenges in efficiently separating and recycling the filter assembly components while minimizing air leakage between the case and the filter, which affects their performance and environmental impact.
Innovation Solution
A filter assembly design featuring a urethane resin-based molding and non-polar polymer cases with a fastening structure, allowing easy detachment and separation of the filter from the case, and incorporating a urethane adhesive to minimize air leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the filter assembly uses a fixed structure where the filter is permanently attached to the case, then air leakage between the case and filter is minimized, but separation and recycling of components becomes difficult
Solution Approach 1:
The filter assembly is divided into separable components: the filter unit and the case are designed as independent parts that can be detached from each other. The filter unit includes a filter element and a molding that can be separated from the case through a detachment structure, enabling easy separation and recycling while maintaining sealing during operation.
Solution Approach 2:
A molding acts as an intermediary component between the filter and the case. The molding is coupled to both the filter and the case, providing a detachment structure that allows controlled separation. This intermediary design enables the filter to be easily removed for recycling while maintaining a sealed connection during normal operation.
2Productivity
If the filter assembly is designed for easy separation of components, then recycling efficiency is improved, but air leakage between case and filter increases
Solution Approach 1:
The molding is pre-coupled to both the filter and the case before operation, creating a pre-assembled sealing unit. This preliminary attachment ensures that when the filter assembly is installed, the sealing interface is already prepared and in place, preventing air leakage while maintaining ease of separation when needed.
Solution Approach 2:
The molding acts as a flexible sealing element between the filter and the case. This flexible component can deform to maintain sealing contact during operation while still allowing for controlled detachment when separation is required, thus preventing air leakage without compromising recyclability.
3Ease of operation
If non-polar polymer material is used for the case, then ease of separation from molding is improved, but adhesion strength during operation may be reduced
Solution Approach 1:
The case is made of non-polar polymer material with specific surface energy characteristics (33 dynes/cm or less) to control adhesion properties. This parameter change in material selection allows the case to be easily detached from the molding while maintaining sufficient adhesion during operation, as the low surface energy prevents excessive bonding.
Solution Approach 2:
The case uses non-polar polymer material combined with appropriate surface treatment or coating to achieve the desired balance between adhesion and detachability. This composite approach allows the material to provide strong bonding during operation while enabling easy separation when needed, resolving the contradiction between strength and ease of detachment.
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 the separation and recycling of filter components, reducing air leakage and improving the overall efficiency and environmental sustainability of air cleaners.
Implementation Method 1
Each of the first case and the second case may comprise a non-polar polymer material... Each of the first molding and the second molding may comprise a urethane resin... The non-polar polymer material may comprise a material having a surface energy of 33 dynes/cm or less
Data Source
AI summary
A filter assembly is disclosed. The filter assembly includes a filter unit including a filter, a first case coupled to a lower end of the filter unit, and a second case coupled to the lower end of the filter unit. The filter unit includes a first molding provided at the lower end of the filter unit and in contact with the first case, and a second molding provided at an upper end of the filter unit and in contact with the second case. Each of the first case and the second case comprises a non-polar polymer material.