Framed Pleated Air Filter Seals for Leak-Free Filtration
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Solution Overview
Problem
Existing air filters in HVAC systems and air purifiers face challenges in effectively sealing pleated filter elements to prevent air leaks around the edges and ends, which can compromise filtration efficiency.
Innovation Solution
A framed air filter design featuring a pleated filter element with edge seals and a perimeter seal made of hardened adhesive, securely bonding the filter to a flattenable-as-made perimeter frame that includes auxiliary fold lines for easy assembly and disassembly, ensuring airtight sealing without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional air filters are used without edge seals and perimeter seals, then the device complexity is low, but air leaks occur around the edges and ends of the pleated filter element, compromising filtration efficiency
Solution Approach 1:
The sealing solution is divided into two distinct segments: edge seals applied to the pleated filter element itself, and a separate perimeter seal applied to the frame. This segmentation allows each seal to address specific leakage points independently, ensuring comprehensive sealing without requiring a completely redesigned integrated system.
Solution Approach 2:
Adhesive materials serve as intermediary substances between the filter elements and frames, creating reliable bonds that prevent air leaks. The edge seals use adhesive to bond the pleated filter element to the frame, while the perimeter seal uses adhesive to seal the frame perimeter, eliminating the need for mechanical fasteners or complex sealing mechanisms.
2Reliability
If additional sealing components are added to prevent air leaks, then air leakage is reduced, but the manufacturing cost and production complexity increase
Solution Approach 1:
The patent employs inexpensive adhesive materials for both edge seals and perimeter seals. These adhesives are applied in simple, straightforward processes that do not require specialized equipment or complex assembly steps. The adhesives cure to form durable seals, providing cost-effective sealing performance without the need for expensive reusable sealing components.
Solution Approach 2:
The manufacturing process merges the sealing function with the existing filter assembly process. Edge seals are applied during pleat formation, and the perimeter seal is applied during frame assembly, combining multiple functions into unified manufacturing steps rather than requiring separate, additional manufacturing operations.
3Stability of the object's composition
If a rigid frame structure is used to support the filter element, then structural stability is high, but the frame cannot be easily collapsed for shipping and storage
Solution Approach 1:
The frame is designed with dynamic characteristics, allowing it to transition between an expanded operational state providing structural stability and a collapsed storage state reducing volume. The frame includes hinge connections and foldable panels that enable controlled deformation, maintaining rigidity when assembled with the filter element but allowing collapse for shipping and storage.
Solution Approach 2:
The frame is segmented into multiple panels connected by hinges, allowing different portions of the frame to move independently during collapse. This segmentation enables the frame to maintain structural integrity when assembled while providing the flexibility to collapse into a compact configuration for shipping and storage.
4Volume of moving object
If the frame is designed to be collapsible for shipping, then shipping volume is reduced, but the structural strength may be compromised
Solution Approach 1:
The frame employs dynamic structural elements including hinges and foldable panels that provide mechanical advantage during collapse while maintaining strength when assembled. The hinge connections are designed to withstand operational loads, and the foldable panels use reinforced edges and corner bracing to maintain structural integrity during both expanded and collapsed states.
Solution Approach 2:
The frame utilizes composite construction combining rigid materials for strength-critical components with more flexible materials for foldable sections. This composite approach allows the frame to achieve both high strength when assembled and low shipping volume when collapsed, with each material optimized for its specific functional requirements.
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 design provides airtight sealing of the pleated filter elements, preventing air leaks and enhancing filtration efficiency, allowing for easy installation and cost-effective production without the need for additional housing or components.
Implementation Method 1
the pleated filter element may comprise two edge seals of hardened adhesive that are positioned proximate, and laterally inward from, each primary, corrugated edge
Data Source
AI summary
A framed air filter including a pleated filter element with two opposing primary, corrugated edges and with two opposing secondary, non-corrugated edges. The pleated filter element bears two edge seals of hardened adhesive that are positioned proximate, and laterally inward from, each primary, corrugated edge. The framed air filter includes a perimeter seal that is made of hardened adhesive and that is disposed on the first side of the pleated filter element. The frame of the framed air filter may be a flattenable-as-made frame.