Air Cleaner Filter Cartridge Sealing With Embedded Frame Blades
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Solution Overview
Problem
Existing straight through flow filters face challenges in maintaining effective seals at flute ends, requiring large sealant surface areas and volumes which can lead to operational issues.
Innovation Solution
The use of z-filter media constructions with a media pack comprising fluted and facing sheets, secured with sealant beads to prevent unfiltered air flow, and a frame with blades embedded within the media pack to enhance sealing and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large sealant surface areas and volumes are used to maintain effective seals at flute ends, then sealing reliability is improved, but device complexity and material consumption increase
Solution Approach 1:
The sealing function is segmented between the sealant beads (which seal the flute ends) and the blades (which provide structural support and positioning). This segmentation allows each component to be optimized independently, reducing the complexity of applying large volumes of sealant while maintaining sealing reliability.
Solution Approach 2:
The blades act as intermediaries between the frame and the media pack, providing a mechanical means to maintain proper spacing and alignment. This intermediary structure reduces the reliance on large amounts of sealant for positioning and sealing, thereby reducing device complexity while maintaining sealing effectiveness.
2Reliability
If large sealant volumes are used to prevent unfiltered air flow, then filtration integrity is improved, but loss of substance increases
Solution Approach 1:
The sealing function is divided between sealant beads applied at flute ends and blades that provide structural containment. This segmentation reduces the total volume of sealant needed while maintaining filtration integrity, as the blades provide mechanical support that prevents unfiltered air leakage without requiring excessive sealant.
Solution Approach 2:
Sealant is applied locally at critical locations (flute ends) rather than uniformly across large surfaces. The blades provide localized structural support where needed, allowing sealant to be used only where it is most effective for preventing unfiltered air flow, thereby reducing overall sealant consumption while maintaining filtration integrity.
3Reliability
If blades are embedded within the media pack to enhance sealing, then sealing quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The blades are positioned and embedded in the media pack during the manufacturing process before final assembly. This preliminary action allows for controlled placement and embedding of the blades, ensuring proper positioning and depth while maintaining manufacturing precision. The blades are integrated into the media pack structure in advance, reducing the precision requirements during final assembly.
Solution Approach 2:
The blades are designed to self-position and self-support within the media pack structure. Their geometry and material properties allow them to maintain proper embedding depth and orientation without requiring complex external fixtures or highly precise machining operations, thereby reducing manufacturing precision requirements while maintaining sealing quality.
Data Source
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AI summary
A filter cartridge (322) includes a media pack (326) having first (336) and second (337) opposite flow faces; the media pack (326) comprising flutes extending in a direction between the inlet flow face (336) and the outlet flow face (337); a frame (336) comprising a base member (368) mounted on the second flow face (337) of the media pack (326); a seal support section (372) extending from the base member (368); and first and second opposite and spaced blades extending from the base member and in a different direction from the base member (368) as the seal support (372) section. The first and second blades (380,381) are embedded within the media pack (326) through the second flow face (337). A seal member (325) is oriented against the seal support section (372). The filter cartridge can be removably oriented in a cassette. The cassette and filter cartridge (322) are removably oriented in an air cleaner housing.