Reusable Multi-Layer HVAC Air Filter for Low Pressure Drop

Solution Overview

Problem

Conventional HVAC system air filters are ineffective in removing airborne molecular contaminants and volatile organic compounds (VOCs) without restricting airflow, leading to increased energy consumption and unnecessary replacement, resulting in significant waste.

Innovation Solution

A multi-panel air filter with a supportive frame and a filter medium comprising multiple layers of unique filtration properties, including electrostatic portions and antimicrobial molecules, is designed to remove airborne molecular contaminants and VOCs while maintaining low air pressure drop and high filtration efficiency, allowing for periodic cleaning and reuse.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional air filters use highly effective filtration materials to remove airborne molecular contaminants and VOCs, then filtration efficiency is improved, but air pressure drop increases and airflow is restricted

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The filter medium is divided into multiple layers, each performing a specific filtration function. The multi-layer structure allows progressive removal of contaminants while maintaining airflow, resolving the contradiction between high filtration efficiency and low energy consumption by distributing the filtration workload across multiple specialized layers rather than using a single high-resistance material

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite filter media combining different materials with complementary properties. The electrostatically charged fibers work synergistically with antimicrobial-coated layers to achieve high removal efficiency for both particulate and gaseous contaminants while maintaining permeability, thus resolving the energy consumption vs. filtration efficiency contradiction

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional air filters use highly effective filtration materials to remove airborne molecular contaminants and VOCs, then filtration efficiency is improved, but air pressure drop increases

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidair pressure drop

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The filter medium is divided into multiple layers, each performing a specific filtration function. The multi-layer structure allows progressive removal of contaminants while maintaining airflow, resolving the contradiction between high filtration efficiency and low energy consumption by distributing the filtration workload across multiple specialized layers rather than using a single high-resistance material

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the filter medium have specialized properties tailored to specific contamination types. Electrostatically charged zones target molecular contaminants and VOCs, while antimicrobial-coated zones handle biological contaminants, allowing high efficiency without uniform high resistance across the entire filter

Inventive Principle:

Principle #3Local quality

3Productivity

If conventional air filters are replaced frequently to maintain airflow and reduce costs, then operational costs are managed, but waste generation increases significantly

Engineering Contradiction:

Improveoperational efficiencyVSAvoidwaste generation

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The filter medium is designed to be reusable through cleaning and regeneration processes. Contaminants are removed from the electrostatic and antimicrobial layers, allowing the filter to be restored to its original performance characteristics and reused multiple times, thereby reducing waste generation while maintaining operational efficiency

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The filter incorporates self-cleaning capabilities through its design, where airflow patterns and pressure differentials facilitate the removal of accumulated contaminants from the filtration layers, extending service life and reducing the frequency of replacement without compromising operational efficiency

Inventive Principle:

Principle #25Self-service

4Productivity

If conventional air filters are replaced frequently to maintain HVAC system performance, then system performance is maintained, but the volume of discarded filters increases

Engineering Contradiction:

ImproveHVAC system performanceVSAvoiddiscarded filter volume

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The filter medium is designed to be reusable through cleaning and regeneration processes. Contaminants are removed from the electrostatic and antimicrobial layers, allowing the filter to be restored to its original performance characteristics and reused multiple times, thereby reducing waste generation while maintaining operational efficiency

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The filter maintains continuous filtration performance through regenerative cleaning cycles rather than requiring complete replacement. The useful action of contaminant removal is sustained over extended periods through repeated cleaning and reuse, reducing the volume of discarded materials while maintaining HVAC system performance

Inventive Principle:

Principle #20Continuity of useful action

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 solution effectively removes airborne contaminants and VOCs with high efficiency and low air pressure drop, extending the filter's lifespan and reducing energy consumption and waste by enabling periodic cleaning and reuse.

Implementation Method 1

configured to remove airborne molecular contaminants and volatile organic compounds (VOCs) from air flowing through the HVAC system

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

filter medium comprising multiple layers of unique filtration properties

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

including electrostatic portions

Methodology Applied

Scientific EffectElectrostatic attraction: Electrostatics

Data Source

PatentUS20220297047A1HVAC Home Air Filter

Publication Date: 2022.09.22 K&N ENGINEERING INC

AI summary

An apparatus and a method are provided for a heating, ventilation, and air conditioning (HVAC) home air filter to remove airborne molecular contaminants and volatile organic compounds (VOCs) from air within residential spaces. The HVAC home air filter includes a supportive frame having a shape and size suitable to orient the HVAC home air filter within a residential HVAC system. A filter medium is retained within the supportive frame to remove the airborne molecular contaminants and VOCs from air flowing through the residential HVAC system. The filter medium includes a combination of media layers configured to exhibit a relatively high filtration efficiency and a low air pressure drop across the filter medium. The supportive frame includes a plurality of elongate sections and corner sections disposed along perimeter edges of the filter medium to support the filter medium within the residential HVAC system so as direct air through the filter medium.