Filter Assembly With Interlocking Housings for Removable Media
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Solution Overview
Problem
Existing filter assemblies require replacement of the entire unit when the filter media is exhausted, leading to increased manufacturing and environmental costs, as well as limitations in using different filter media types or lifespans, due to the need for adhesive securing of finer filter media like HEPA.
Innovation Solution
A filter assembly design featuring inter-engageable housings that allow for removable and reusable filter media, forming a seal without additional adhesives, enabling the use of various filter media types and lifespans, and innovative packaging methods to protect and space-efficiently store filter media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to secure filter media in filter assembly, then filter media is securely held, but entire filter assembly must be replaced when filter media is exhausted
Solution Approach 1:
The filter assembly is divided into separate components: a reusable housing and a replaceable filter media element. The housing contains sealing surfaces and structural support, while the filter media is mounted on a frame that can be independently removed. This segmentation allows the filter media to be replaced without replacing the entire assembly, resolving the contradiction between secure retention and replaceability.
Solution Approach 2:
The filter media element is extracted as a separate removable component from the housing. The housing retains the sealing surfaces and structural elements, while the filter media with its frame can be independently removed and replaced. This extraction eliminates the need to replace the entire assembly when filter media is exhausted.
2Reliability
If adhesive is used to secure filter media, then filter media is firmly attached, but manufacturing cost and time increase
Solution Approach 1:
The adhesive is removed from the system entirely. Instead of bonding the filter media to the housing with adhesive, the filter media is secured to a frame structure that mechanically interfaces with the housing through sealing surfaces and engagement features. This eliminates the manufacturing steps and costs associated with applying and curing adhesive.
Solution Approach 2:
The chemical bonding mechanism (adhesive) is replaced with a mechanical retention system. The filter media frame includes sealing surfaces and engagement features that mechanically secure the filter media in place without requiring adhesive bonding, reducing manufacturing complexity and cost.
3Reliability
If adhesive is used to secure filter media, then filter media is fixed in position, but environmental impact increases
Solution Approach 1:
Adhesive materials are completely removed from the system. The filter media is positioned and secured using mechanical features of the frame and housing structure, eliminating the need for chemical adhesives that contribute to environmental pollution and waste.
Solution Approach 2:
The reusable housing and frame structure are designed to be retained and reused after filter media replacement, while only the consumable filter media is discarded. This reduces waste compared to replacing the entire assembled unit, and eliminates adhesive waste from the replacement process.
4Reliability
If entire filter assembly is replaced when filter media is exhausted, then filter media function is maintained, but manufacturing and environmental costs increase
Solution Approach 1:
The filter assembly is segmented into reusable housing and replaceable filter media elements. Only the filter media portion needs to be replaced when exhausted, while the housing and frame structure are retained for future use, significantly reducing material waste and manufacturing costs.
Solution Approach 2:
The reusable components (housing, frame structure) are recovered and retained after filter media replacement, while only the consumable filter media is discarded. This recovery and reuse approach reduces manufacturing material waste and environmental impact.
5Reliability
If adhesive is used to secure filter media, then filter media is fixed securely, but filter assembly complexity increases
Solution Approach 1:
The adhesive bonding system is extracted and replaced with a mechanical retention system. The filter media frame includes sealing surfaces and engagement features that provide secure fixation through mechanical means, simplifying the overall assembly structure by eliminating adhesive application requirements.
Data Source
AI summary
A filter assembly has a first housing having a plurality of recesses provided therein and a second housing having a plurality of ribs provided on an inner surface thereof. When the first and second housings are in an engaged configuration, the ribs are receivable in the recesses of the first housing thereby securing a filter media in the filter assembly.