Flexible Air Filter with Nested Accordion Folds

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Solution Overview

Problem

Conventional air filters are rigid and lack flexibility, requiring specific sizes for each application, leading to increased costs and inefficiencies in shipping and storage due to their fixed dimensions, which limits their interchangeability and convenience for consumers.

Innovation Solution

The development of an air filter with flexible attributes that can bend and fold along both the X and Y axes, utilizing flexible material inserts to reduce volume during shipping while maintaining the ability to expand to standard sizes, allowing for more efficient shipping and storage through the use of accordion folds and tri-fold configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional rigid air filters are used, then they provide effective air filtration, but they require multiple sizes and cannot be folded for efficient shipping and storage

Engineering Contradiction:

Improveflexibility and interchangeability of air filterVSAvoidshipping and storage volume of air filter

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The air filter transitions from a rigid static structure to a dynamic flexible structure that can change its configuration between extended operational state and compact folded state for shipping and storage, allowing a single filter to adapt to different size requirements

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The air filter panels are folded into a nested compact configuration for shipping and storage, similar to nested dolls, where multiple layers are compressed into a smaller volume while maintaining the ability to expand to full size when deployed

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If multiple sizes of air filters are manufactured to fit different openings, then all structures can be supplied, but consumers face expense and complexity in managing various sizes

Engineering Contradiction:

Improvefitting capability for different openingsVSAvoidnumber of different filter sizes to manage

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single universal air filter design with flexible panels can be folded to fit multiple different opening sizes, replacing the need for consumers to manage multiple specialized filter sizes for different HVAC systems and openings

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The air filter is divided into multiple flexible panels that can be folded and configured in different arrangements to adapt to various opening dimensions, allowing one filter to perform the function of multiple fixed-size filters

Inventive Principle:

Principle #1Segmentation

3Reliability

If rigid components are used to create an effective fit, then the air filter seals properly, but the filter cannot be folded or compressed

Engineering Contradiction:

Improvesealing effectiveness of air filterVSAvoidfoldability and compressibility of air filter

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The air filter uses flexible panels with integrated sealing edges that can bend and fold while maintaining sealing effectiveness, replacing rigid components with flexible materials that provide both compliance for folding and reliability for sealing

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS11806656B2Folding air filter assembly and apparatus

Publication Date: 2023.11.07 FILTEREASY LLC (100 00)

AI summary

This document presents an apparatus for a flexible air filter media that can be configured for shipping and storage having one or more flexible inserts mounted to the filter media along one or more portions of the accordion folds of the air filter material. The current invention permits the air filter apparatus to fold along both X and Y axes, create a tri-fold, and bend in a manner that provides for a much smaller volume for shipping purposes. The invention also permits attaching the flexible material to the center of the filter media and also inserts which allow sections of the air filter media to be nested one into another to reduce both shipping and storage volume.