Integral Filter Retaining Rack to Reduce Assembly Time and Footprint
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Solution Overview
Problem
Conventional air filter retaining assemblies are inefficient due to their larger footprint caused by designing filter cavities based on nominal sizes rather than actual dimensions, leading to space constraints in air handling units and reduced filtration efficiency, as they require additional structural reinforcement and alignment holes, which increases assembly time and cost.
Innovation Solution
An integral filter retaining rack with interlocking hem slot bars and brake slot bars, formed from single-sheet double-panel flat bodies with flanges and slots, providing a self-supportive and compact assembly that fits actual filter sizes without additional reinforcement, allowing for scalability and efficient filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If filter cavities are designed based on nominal sizes, then the assembly can accommodate standard filters, but the footprint becomes larger than needed
Solution Approach 1:
The patent transitions from designing filter cavities based on nominal filter sizes to designing based on actual physical dimensions. This parameter change allows the cavity to precisely match the filter being held, eliminating the excess space that occurs when nominal dimensions are used as the design basis.
2Ease of manufacture
If individual frames are aligned using indentations or guide holes and fastened together, then the assembly can be constructed, but assembly time and labor increase
Solution Approach 1:
The patent merges multiple individual frame components into a single integral filter retaining rack. This consolidation eliminates the need for separate alignment holes, guide holes, and fastening operations that would be required to assemble multiple frames together, thereby reducing assembly time and labor.
Solution Approach 2:
The integral rack is designed with built-in alignment features and compartment definitions that segment the filter holding spaces without requiring separate frame assemblies. This segmentation is integrated into the single piece structure, avoiding the need to align and fasten multiple components.
3Strength
If stiffener bars are added to larger filter assemblies, then structural rigidity is improved, but the effective filter surface area is reduced
Solution Approach 1:
The patent combines the structural support function with the filter retaining structure by designing an integral rack where the walls themselves provide the necessary rigidity. This eliminates the need for separate stiffener bars that would protrude into the filter cavity and reduce the effective filter surface area.
4Reliability
If conventional filter retaining assemblies are used, then filters can be held and sealed, but the assembly size increases reducing space efficiency
Solution Approach 1:
The patent changes the design parameter from nominal filter dimensions to actual physical filter dimensions. This ensures the cavity is sized precisely to the filter, maximizing the use of available space while maintaining proper filter retention and sealing capabilities.
Data Source
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.