Folded Air Filter Frame With Bowed Inner Edge for Leak Prevention
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Solution Overview
Problem
Conventional framed air filters face challenges in maintaining structural rigidity and preventing air leaks, especially at corners, which can lead to reduced filtration efficiency and increased maintenance needs.
Innovation Solution
The use of a wrapped frame design with foldably connected panels and corner-stabilizing features such as locking tabs, receiving slots, and bowed inner edges enhances the structural integrity and stability of the frame, preventing unfolding and air leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional framed air filter design is used, then the frame structure is simple and easy to manufacture, but the frame lacks structural rigidity and is prone to air leaks at corners
Solution Approach 1:
The frame is divided into multiple panels that are foldably connected together, allowing the frame to be constructed from segmented components that can be assembled into a rigid structure while maintaining manufacturing simplicity
Solution Approach 2:
Corner pieces are nested within corner recesses of adjacent frame portions, with locking tabs engaging into receiving slots to create a interlocked corner structure that enhances rigidity without significantly increasing overall complexity
2Reliability
If the frame is made more rigid to prevent air leaks, then filtration efficiency improves, but assembly complexity increases
Solution Approach 1:
The frame structure is designed to be self-stabilizing, where the bowed inner edge geometry and interlocking corner pieces automatically maintain structural integrity and prevent air leaks without requiring additional active components or complex assembly procedures
Solution Approach 2:
The inner edge of the frame is given a bowed curvature rather than being perfectly flat, which provides structural rigidity and helps prevent air leaks while maintaining a relatively simple flat panel construction that is easy to assemble
Data Source
AI summary
A framed air filter, comprising an air filter media having a generally rectangular perimeter with four major edges, and a frame comprising four frame portions. Each frame portion of the frame is mounted on one of the four major edges of the air filter media and met with neighbouring frame portions to form corners of the frame. At least one of the frame portions is provided by a frame piece that comprises first, second, third and fourth panels that are foldably connected by fold lines, which single frame piece is wrapped in a generally rectangular configuration so that the fourth panel comprises a forward terminal end that is abutted proximal a rearward major surface of the first panel. The third panel provides a rear wall of the frame portion with an inner edge provided by a fold line connecting the third panel to the fourth panel, wherein the inner edge is bowed.