Framed Air Filter with Segmented Support Grill

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Solution Overview

Problem

Non-self-supporting air filter media in residential HVAC systems fail to withstand the forces of forced air flow, leading to unacceptable deformation, rupture, or dislodgment without a support frame and grill.

Innovation Solution

A framed air filter design featuring a non-self-supporting air filter media with a support frame and a separate, non-integral perforate support grill attached to the frame, providing structural support and preventing deformation or rupture under air pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If non-self-supporting air filter media is used, then material flexibility and cost are improved, but structural strength and resistance to air pressure are worsened

Engineering Contradiction:

Improvematerial usageVSAvoidframe strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The support structure is divided into two separate components: a support frame and a support grill. The frame provides the primary structural skeleton while the grill provides additional support across the filter media surface. This segmentation allows each component to be optimized independently for its specific function while using thinner materials overall.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines multiple materials with different properties: the support frame uses thicker gauge material for structural integrity, while the support grill and filter media use thinner materials for flexibility and cost. This composite approach creates a system where the overall strength is sufficient while minimizing total material usage.

Inventive Principle:

Principle #40Composite materials

2Strength

If a separate non-integral support grill is added to the frame, then structural support and resistance to deformation are improved, but device complexity is worsened

Engineering Contradiction:

Improveresistance to deformationVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The support grill is attached to the support frame to create a unified support system. While the components are separate, their combination provides enhanced structural support without requiring a completely different design approach. The grill merges with the frame functionally to prevent media deformation while maintaining manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If thicker materials are used for the frame, then structural strength is improved, but material cost and weight are worsened

Engineering Contradiction:

Improveframe strengthVSAvoidmaterial thickness

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

Thicker gauge material is used only where structurally necessary in the support frame, while thinner materials are used for the support grill and filter media. This local differentiation of material thickness optimizes strength where needed while minimizing material usage and cost in areas where full strength is not required.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8979966B2Framed air filter and method of making

Publication Date: 2015.03.17 3M INNOVATIVE PROPERTIES CO

AI summary

A framed air filter and method of making. The framed air filter includes a non-self-supporting air filter media with a generally rectangular perimeter with four major edges, a support frame comprised of four support frame portions each portion being mounted on one of the four major edges of the non-self-supporting air filter media, and a support grill that is attached to each of the four portions of the support frame but that is not integral with any portion of the support frame.