Integral Filter Rack Structure for Compact Air Handling Units
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Solution Overview
Problem
Conventional air filter retaining assemblies are inefficient due to their larger footprint, requiring additional structural reinforcement and reducing airflow efficiency when space is constrained in air handling units, as they are designed for nominal filter sizes rather than actual dimensions.
Innovation Solution
An integral filter retaining rack with interlocking hem and brake slot bars, formed from single sheet materials with flanges and slots, providing a self-supportive and scalable design that eliminates the need for additional reinforcement and aligns with actual filter sizes, allowing for efficient use of space and reduced assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional filter retaining assemblies are designed for nominal filter sizes, then filter retention is achieved, but the assembly footprint becomes larger than necessary
Solution Approach 1:
The patent changes the design parameter from nominal filter sizes to actual physical filter dimensions. The filter rack is designed with precise dimensions matching the actual filter size (e.g., 24x24x10 inches) rather than nominal sizes, eliminating the extra space required by conventional designs and reducing the overall assembly footprint.
Solution Approach 2:
The filter rack is segmented into multiple individual filter compartments within a single integrated structure. This allows the rack to accommodate multiple filters of precise dimensions while maintaining a compact overall footprint, as each compartment is optimized for the actual filter size rather than requiring additional space for nominal sizing conventions.
2Ease of manufacture
If individual frames are fastened together using rivets, screws or other fasteners, then structural assembly is achieved, but assembly time and labor increase
Solution Approach 1:
The patent merges multiple individual frame segments into a single integral filter rack structure. The rack is constructed as one continuous piece with interlocking compartments, eliminating the need to assemble separate frames with fasteners. This integral construction reduces assembly time and labor while maintaining structural integrity through the unified design.
3Strength
If stiffener bars are added to larger filter assemblies, then structural rigidity is improved, but filter surface area is reduced and efficiency is lowered
Solution Approach 1:
The patent combines the structural support function with the filter rack structure itself. The integral rack design incorporates internal reinforcement through its unified construction, eliminating the need for separate stiffener bars. This allows the full filter surface area to be utilized for filtration without being blanked off by reinforcement elements.
Solution Approach 2:
The rack design incorporates localized reinforcement features at specific critical points within the integral structure, such as at compartment intersections or support locations, rather than requiring universal stiffener bars across the entire assembly. This provides necessary rigidity while preserving maximum filter surface area.
4Ease of manufacture
If alignment holes and fastening operations are used to construct filter retaining assemblies, then frame alignment is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple frame segments into a single integral structure that is manufactured as one piece. This eliminates the need for alignment holes and fastening operations entirely, as there are no separate components to join. The unified construction inherently provides precise alignment without requiring additional alignment features or assembly steps.
Data Source
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AI summary
The invention pertains to a filter retaining assembly which is rigid and self-supportive without requiring any additional structural reinforcement. The design maximizes the filter surface to be used for air filtration and increases the filtration efficiency. The invention is also designed to minimize the filter assembly size to fit into the valuable space when the air handling unit physical dimension is constrained. The invention uses integral construction methods to save assembly time and labor by eliminating the need of using alignment holes and fastening each individual frame to construct a conventional filter retaining assembly. The proposed method maintains flexibility of scaling to any filter size and quantity.