Integral Filter Casing Structure for Rust-Free Air Filtration
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Solution Overview
Problem
Conventional air conditioner filters made of carbon steel require complex machining processes, are prone to rust, and have a short casing design that limits the effective filtering area, leading to poor filtering effects and production inefficiencies.
Innovation Solution
An integrally formed filter casing made from materials like stainless steel or copper, with a design that eliminates the need for splicing and reduces the risk of leakage, featuring a transition tube connection that is welded at a high temperature and a filter screen assembly with U-shaped support strips for enhanced strength and filtering efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If carbon steel is used for the filter casing, then the material cost is low, but the casing is prone to rust and requires coating which complicates the manufacturing process
Solution Approach 1:
The patent changes the material parameter from carbon steel to stainless steel or copper, which fundamentally alters the corrosion resistance properties. This material substitution eliminates the need for protective coatings and reduces manufacturing complexity despite higher material cost, resolving the contradiction between material cost and process complexity.
Solution Approach 2:
The patent employs stainless steel or copper as alternative materials that inherently combine structural integrity with corrosion resistance. These composite or alloy materials eliminate the need for additional coating layers, simplifying the manufacturing process while maintaining low material cost through integrated functionality.
2Reliability
If the casing is welded at low temperature, then the coating on the casing is less damaged, but the coating is easy to burn out when the filter is welded to external copper tube later, causing leakage risks
Solution Approach 1:
The patent applies beforehand cushioning by using stainless steel or copper casings that do not require protective coatings in the first place. This preventive approach eliminates the vulnerability of coatings to burning during subsequent welding operations, ensuring both coating integrity and preventing leakage risks without compromising reliability.
3Length of moving object
If the casing is made shorter, then the manufacturing cost is reduced, but the filter screen area becomes small resulting in poor filtering effect
Solution Approach 1:
The patent addresses the contradiction by optimizing the dimensional proportions of the casing, particularly increasing the diameter or width dimension while maintaining a compact length. This dimensional adjustment allows the filter screen area to be sufficiently large for effective filtration while keeping the overall casing length short, thus maintaining manufacturing cost efficiency without compromising filtering precision.
4Productivity
If an integrally formed casing is used, then the manufacturing steps are simplified and production efficiency is raised, but the material cost increases
Solution Approach 1:
The patent applies merging by integrating the casing into a single integral structure made of stainless steel or copper, eliminating the need for separate coating components and assembly steps. This consolidation simplifies the manufacturing process and raises production efficiency, while the use of durable materials reduces long-term maintenance costs, balancing the initial material cost increase against productivity gains.
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
Simplifies manufacturing processes, improves production efficiency, enhances corrosion resistance, and increases the effective filtering area, resulting in a more reliable and efficient air filtration system.
Implementation Method 1
the transition tube is fixed to the straight tube section by welding
Data Source
AI summary
A filter, a manufacturing method for a filter, and an air conditioner are provided. The filter includes a casing, a transition tube, and a filter screen assembly. The filter screen assembly is provided in the casing, fitted with and connected to an inner wall of the casing, the casing is an integrally formed piece, and two axial ends of the casing have neck sections, and two neck sections are both fixedly connected to the transition tube.