Filter, manufacturing method for filter and air conditioner
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Solution Overview
Problem
Conventional air conditioner filters made of carbon steel require complex machining processes, are prone to rust, and have a short casing design that limits the effective filtering area, leading to poor filtering efficiency and risks of leakage due to coating burnout during welding.
Innovation Solution
An integrally formed filter casing made from materials like stainless steel or copper, with neck sections for connection to a transition tube, and a filter screen assembly that includes U-shaped support strips for enhanced strength and larger filtering area, eliminating the need for splicing and surface coating, and allowing high-temperature welding for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If carbon steel is used for the filter casing, then the material cost is reduced, but the casing requires surface coating to prevent rust, increasing manufacturing complexity and reducing production efficiency
Solution Approach 1:
The patent changes the material parameter from carbon steel to stainless steel or copper, which inherently possess corrosion resistance. This eliminates the need for surface coating processes while maintaining cost-effectiveness, as these materials are widely available and can be formed using standard manufacturing processes.
Solution Approach 2:
The invention extracts and eliminates the surface coating step from the manufacturing process. By selecting materials with inherent corrosion resistance, the patent removes the harmful factor of rust prevention requirements, simplifying the manufacturing process to only include forming and welding operations.
2Quantity of substance
If the casing is made shorter to reduce material usage, then the manufacturing cost decreases, but the filter screen area becomes insufficient, reducing filtering effectiveness
Solution Approach 1:
The patent extends the casing in the axial dimension rather than increasing radial dimensions. By making the casing longer along the airflow direction, the filter screen area is increased without proportionally increasing material consumption, as the extended portion utilizes the existing radial cross-section efficiently.
Solution Approach 2:
The patent introduces a telescopic or expandable structure within the casing that allows the filter screen assembly to be adjusted or extended. This dynamic configuration enables the system to provide sufficient filtering area while maintaining a compact external casing dimensions, optimizing material usage.
3Reliability
If the casing is welded at low temperature to preserve the coating, then the coating integrity is maintained, but the welding strength is insufficient, increasing leakage risk
Solution Approach 1:
The patent converts the potential harm of high-temperature welding (which would damage coatings) into a benefit by eliminating the coating requirement entirely. Using stainless steel or copper allows high-temperature welding processes that produce strong, reliable joints without any coating to protect, turning the welding heat from a harmful factor into an acceptable process parameter.
Solution Approach 2:
The invention uses composite construction where the casing material (stainless steel or copper) provides both structural strength and corrosion resistance. This composite approach combines the benefits of high weldability and inherent protective properties, eliminating the need for separate coating layers and enabling optimal welding temperatures for maximum joint strength.
4Productivity
If an integrally formed casing is used instead of spliced sections, then the manufacturing steps are reduced and production efficiency increases, but the manufacturing equipment complexity increases
Solution Approach 1:
The patent changes the material parameter to stainless steel or copper, which have favorable formability characteristics that allow integral forming using standard equipment. These materials can be shaped into complex geometries through conventional forming processes, avoiding the need for specialized or overly complex manufacturing equipment while achieving high production efficiency.
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
Simplifies manufacturing, improves production efficiency, enhances corrosion resistance, and increases the effective filtering area, reducing the risk of leakage and improving filtering performance while eliminating the need for surface coatings.
Implementation Method 1
the casing being an integrally formed piece... eliminating the need for splicing and surface coating, and allowing high-temperature welding for secure connections
Implementation Method 2
the transition tube is fixed to the straight tube section by welding
Data Source
AI summary
A filter, a manufacturing method for a filter, and an air conditioner are provided. The filter includes a casing (10), a transition tube (20), and a filter screen assembly (30). The filter screen assembly (30) is provided in the casing (10), fitted with and connected to an inner wall of the casing (10), the casing (10) is an integrally formed piece, and two axial ends of the casing (10) have neck sections (11), and two neck sections (11) are both fixedly connected to the transition tube (20).