Flexible Wire-Frame Filter Assembly for Tight HVAC Access
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Solution Overview
Problem
Existing HVAC systems face challenges with rigid filter elements that require frequent replacement, lead to contaminated airflow, and are prone to damage due to limited access and environmental concerns, especially in supermarket refrigeration units where space restrictions and cardboard superstructures cause issues.
Innovation Solution
A flexible filter element is fabricated on-site using wire frames flexibly attached with spring connectors to fit the original equipment manufacturer's housing dimensions, allowing for custom size adjustment and easy assembly, with end-caps for protection during handling and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid filter elements with cardboard superstructure are used, then structural support is provided, but rigidity deteriorates during high humidity conditions or rainstorms causing the filter to be drawn into the fan
Solution Approach 1:
The patent changes the material parameter from cardboard to wire frame, which maintains structural support while being immune to humidity degradation. The wire frame's physical properties remain stable across different humidity conditions, preventing the filter from being drawn into the fan.
Solution Approach 2:
The patent uses a composite structure combining wire frame with filter media, creating a hybrid construction that leverages the strength and humidity resistance of wire while providing the filtering function of the media. This composite approach resolves the contradiction between needing structural support and avoiding humidity-related failure.
2Length of moving object
If long filter elements are used for supermarket refrigeration units, then adequate filtration is achieved, but insertion becomes impossible without moving the unit due to limited access space
Solution Approach 1:
The patent divides the long filter element into multiple shorter wire frame sections that can be assembled on-site. This segmentation allows the filter to be constructed to the required length while maintaining ease of installation, as each section can be maneuvered into place through limited access spaces and then connected to form the complete long filter.
Solution Approach 2:
The patent employs flexible wire frame construction that allows the filter structure to be dynamically adjusted during installation. The wire frame can be bent, folded, or reconfigured to navigate around obstacles and fit through restricted access areas, then stabilized into its final rigid configuration once installed.
3Ease of manufacture
If replacement filter elements are used with standard tolerances, then manufacturing is simplified, but significant contaminated airflow circulates around the filter elements
Solution Approach 1:
The patent applies local quality by creating a custom-fit wire frame structure that conforms precisely to the specific filter housing geometry. Rather than using a standard tolerance approach throughout, the wire frame is customized locally to match the unique contours and dimensions of the housing, ensuring complete sealing and eliminating contaminated airflow paths.
4Strength
If cardboard superstructure is used for filter elements, then rigidity is provided, but wood fiber is consumed which is not environmentally conservative
Solution Approach 1:
The patent replaces the disposable cardboard superstructure with a durable wire frame that can be reused across multiple filter media replacements. This eliminates the continuous consumption of wood fiber associated with cardboard while maintaining the necessary structural support, thereby reducing material waste and environmental impact.
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
This solution enables a positive air seal, reduces maintenance frequency, protects the filter from damage, and is environmentally friendly by eliminating the need for cardboard superstructures, while allowing for precise length adjustment and easy installation in restricted spaces.
Implementation Method 1
one or more wire frames are flexibly fastened to one another to form a structure substantially conforming to the unit's original equipment manufacturer's filter housing
Data Source
AI summary
An air filter element partially-fabricated on site wherein one or more wire frames are fastened to one another to form a structure substantially conforming to the dimensions of the original equipment manufacturer's filter housing. One or more of the wire frames are flexibly attached to each other end-to-end by flexible attachment means, allowing the assembled filter unit to be inserted into the filter housing one frame at a time, with the frame sections yet to be inserted folded or directed off to one side, thus bypassing space restrictions. Flexible attachment means may comprise spring connectors. Also disclosed is an end-cap affixed to or formed at one or both ends of the filter element. The end-caps may also contain printed material, such as text or pictures, which may include instructions for use, identifying labels or symbols, or the like.