Open-Cell HVAC Filter With Breakaway Sections for Custom Fit
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Solution Overview
Problem
Conventional HVAC air filters are inefficient in removing airborne molecular contaminants and volatile organic compounds, require a wide range of sizes to fit various HVAC systems, and are cumbersome to install and maintain, leading to inventory challenges and reduced filtering efficiency over time.
Innovation Solution
A filter made from air-transmissive open-cell polymeric material, such as foamed polyurethane, with a rectangular configuration and removable cubical members that can be easily cut and adapted to fit different HVAC system sizes without tools, providing superior filtration efficiency and reducing inventory needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pleated-paper filters are used in HVAC systems, then airflow is maintained, but filtering efficiency for airborne molecular contaminants and volatile organic compounds is low
Solution Approach 1:
The patent employs an open-cell foam material with controlled porosity to achieve superior filtration. The foam structure provides numerous interconnected pores that trap airborne particles and molecular contaminants while maintaining airflow. This porous structure enables the filter to capture contaminants that conventional pleated-paper filters cannot, directly resolving the contradiction between maintaining airflow and improving filtration efficiency for molecular contaminants.
Solution Approach 2:
The invention uses a composite structure combining the open-cell foam matrix with embedded filtering media or coatings. This composite approach integrates the structural integrity and airflow properties of the foam with the high-efficiency contaminant capture capabilities of specialized filtering materials, achieving both high MERV rating and volatile organic compound removal while maintaining breathability.
2Adaptability or versatility
If a wide range of filter sizes are produced to fit various HVAC systems, then adaptability is improved, but inventory complexity and costs increase
Solution Approach 1:
The filter is designed as a modular assembly of discrete components including the foam core, filtering media layers, and framing elements. These segmented components can be independently manufactured in standardized sizes and then configured to create custom-fit filters for different HVAC systems. This segmentation allows suppliers to maintain simpler inventory of modular parts rather than producing every possible full filter size combination.
Solution Approach 2:
The open-cell foam material possesses inherent flexibility and compressibility that allows the filter to dynamically adapt to different HVAC system dimensions. The foam can be compressed to fit tighter spaces or expanded to fill larger openings, providing a degree of size adaptability without requiring precise manufacturing of multiple rigid size variants. This dynamic property reduces the need for extensive inventory while maintaining versatility.
3Strength
If filters are made rigid to maintain structural integrity, then strength is improved, but ease of installation and adaptation to different sizes is reduced
Solution Approach 1:
The filter incorporates a flexible foam-based shell structure that provides sufficient structural integrity to maintain its shape and filtering function while allowing for easy manipulation during installation. The foam's inherent flexibility enables the filter to be bent, compressed, and shaped to fit various HVAC system configurations without requiring rigid framing that would complicate installation. This flexible shell maintains strength where needed while providing ease of operation during installation and adaptation.
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 filter effectively captures airborne particles and volatile organic compounds with a MERV value of 11, is easy to install and maintain, and reduces inventory costs by allowing for quick adaptation to various system sizes, while maintaining airflow efficiency and extending filter life.
Implementation Method 1
The body is formed entirely of an air-transmissive open-cell polymeric material... effectively captures airborne particles and volatile organic compounds
Implementation Method 2
The body is formed entirely of an air-transmissive open-cell polymeric material... superior filtration efficiency
Data Source
AI summary
A filter for an HVAC system has a body formed entirely of an air-transmissive open-cell polymeric material. The body is of a generally rectangular configuration. The body has a plurality of cuts extending entirely through a thickness of the body from the top to the bottom of the body. The plurality of cuts define a plurality of cubical members frangibly connected together such that each of the plurality of cubical members is separable by hand from a remainder of the body such that an individual cubical member is removable along both a portion of a length and a portion of a width of the body.