Flexible Return Air Seal Assembly to Prevent Filter Bypass Leakage
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Solution Overview
Problem
Existing return air filter assemblies in forced air systems suffer from gaps between the filter and the frame, allowing unfiltered air to bypass the filter as it clogs, necessitating a seal that restricts air passage around the filter for complete filtration.
Innovation Solution
A return air seal assembly comprising flexible seals that wrap around the vent frame assembly, providing compressive force on the filter to secure it in place and forming a seal on multiple surfaces, including a tubular body with channels to fit various frame configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is installed in a return air vent frame assembly, then air filtration is achieved, but gaps between the filter and frame allow unfiltered air to bypass the filter
Solution Approach 1:
The patent applies a flexible seal member that wraps around the filter assembly and contacts the frame at multiple locations. This flexible film creates a sealing barrier between the filter and frame, preventing air leakage while accommodating variations in frame geometry and filter dimensions.
Solution Approach 2:
The seal member extends in multiple dimensions, wrapping around the filter from the downstream side and making contact at multiple surfaces including the upstream side. This multi-dimensional sealing approach blocks air leakage paths that exist in various directions around the filter-frame interface.
2Reliability
If a seal is added to prevent air leakage, then filtration effectiveness improves, but device complexity increases
Solution Approach 1:
The seal member is divided into multiple functional segments or zones that perform different sealing functions at different locations. The seal wraps around the filter and makes contact at multiple discrete points along the frame, with each segment contributing to the overall sealing effectiveness while maintaining simplicity.
Solution Approach 2:
The seal member serves multiple functions simultaneously: it seals the gap between filter and frame, provides structural support for the filter assembly, and guides the filter into proper position during installation. This multi-functionality reduces the need for separate components.
3Reliability
If the seal contacts the frame on multiple surfaces, then sealing effectiveness improves, but manufacturing precision requirements increase
Solution Approach 1:
The seal member is designed with variable cross-sectional dimensions and material properties that allow it to adapt to different frame geometries. The flexible material can deform to accommodate dimensional variations within a range of tolerances, reducing the need for tight manufacturing precision while maintaining effective sealing contact at multiple surfaces.
Solution Approach 2:
The flexible nature of the seal member allows it to conform to slight variations in frame dimensions and surface irregularities. This flexibility compensates for manufacturing tolerances in both the frame and seal, enabling reliable multi-surface contact without requiring extremely tight dimensional control.
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
The seal assembly effectively prevents air leakage around the filter, ensuring all air is filtered through the filter by compressing it against the frame, enhancing filtration efficiency.
Implementation Method 1
provide a compressive force on a filter within the frame assembly to secure the filter in the frame opening
Implementation Method 2
A return air seal assembly is provided including a first seal and a second seal that are configured to wrap around a filter frame assembly
Data Source
AI summary
A return air seal assembly includes a flexible body that is formed from one or more members that includes a compression member coupled to a first arm at a first edge and a second arm coupled to the first arm at a distal end opposite the first edge. The flexible return air seal is configured to wrap around a return vent assembly opening so as to locate a seal between the air filter and the frame. The compression member flexes to create a seal with the filter to eliminate the passage of air around the filter. The seal assembly wraps around multiple surfaces of an angled filter arm of the frame.