Filter Frame Assembly with Integrated Gasket Carrier
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Solution Overview
Problem
Current HVAC filters face inefficiencies due to air bypass issues, which reduce their particle capture effectiveness and increase operational costs, especially in high-efficiency filters, where leaks can lead to compromised air quality and equipment damage.
Innovation Solution
A filter frame assembly with a pre-installed gasket carrier that provides consistent sealing across multiple orientations and filter-rack styles, reducing installation time and enhancing sealing efficacy by using a snap feature, clip feature, or adhesive attachment to minimize air bypass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate gasket kits are provided with high-efficiency filters, then sealing performance can be improved, but installation complexity and time increase
Solution Approach 1:
The gasket is integrated directly into the filter frame assembly, merging two separate components (filter frame and gasket) into a single unified structure. This eliminates the need for separate gasket kits and their associated installation steps, while maintaining the sealing function.
Solution Approach 2:
The gasket is pre-installed and pre-positioned on the filter frame during manufacturing, before the filter reaches the installation site. This preliminary action ensures proper gasket placement and eliminates the need for installers to manually apply and position gaskets, reducing installation complexity.
2Reliability
If adhesive backed foam strips are used for gasketing, then sealing can be achieved, but proper placement requires specific knowledge and time
Solution Approach 1:
The gasket is pre-positioned on the filter frame during manufacturing with the correct orientation and placement. The carrier structure includes features that guide proper installation orientation, eliminating the need for installers to have specialized knowledge about gasket placement.
Solution Approach 2:
The gasket carrier acts as an intermediary structure that holds the gasket in the correct position and facilitates easy transfer to the filter frame. The carrier includes alignment features and attachment mechanisms that ensure proper placement without requiring installer expertise.
3Ease of manufacture
If filters are designed without integrated gasketing, then manufacturing simplicity is maintained, but air bypass and filtering efficiency are compromised
Solution Approach 1:
The gasketing function is merged into the filter frame assembly through integration of the gasket and carrier structure, ensuring that sealing is an inherent part of the filter design rather than an optional add-on, thereby maintaining filtration efficiency.
Solution Approach 2:
The integrated gasket carrier design serves multiple functions: it provides sealing, facilitates easy installation, ensures proper orientation, and works with various filter rack styles. This multi-functionality maintains manufacturing efficiency while improving reliability.
Data Source
AI summary
A filter frame assembly is disclosed comprising a perimeter member surrounding a fluid aperture adapted to accommodate a fluid flow from an upstream direction to a downstream direction, the perimeter member comprising a perimeter upstream surface, a perimeter downstream surface, and a perimeter outer surface connecting the perimeter upstream surface to the perimeter downstream surface. A gasket carrier is attached to the perimeter member and comprises a carrier outer portion facing generally away from the fluid aperture and a first outer portion sealing member projecting from the carrier outer portion.