Interlocking Filter Bank Assembly to Prevent HVAC Airflow Bypass
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Solution Overview
Problem
There is a need for a fast assembly, adaptable particulate filtration system that provides 95% filtration efficiency in various sizes and shapes for heating, ventilation, and air conditioning systems, while preventing airflow bypass and providing extra support between filters to reduce maintenance time and ensure effective filtration.
Innovation Solution
A non-deforming particulate filtration bank composed of interlocking filters with a one piece non-rigid flexible integral locking mechanism, featuring non-adhesive single or double projection portions for quick connect and quick disconnect functionality, which connects pleated filter media supported by frames without the need for clips or glue, ensuring efficient airflow and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional filtration systems are used, then filtration efficiency can be achieved, but assembly time is excessive and adaptability to various sizes and shapes is limited
Solution Approach 1:
The filtration system is divided into multiple individual filter units that can be independently assembled. Each filter unit contains a filter media supported by a frame structure, allowing modular assembly into banks of various configurations. This segmentation enables rapid assembly while maintaining adaptability to different sizes and shapes by simply varying the number and arrangement of individual units.
Solution Approach 2:
The filter frame design incorporates universal features including standardized corner members with receiving structures, and support members with tabs that can engage with corresponding slots in adjacent frames. This universal design allows the same basic filter unit structure to be adapted for various sizes and shapes by adjusting the number of units and their arrangement, while maintaining consistent assembly methods across all configurations.
2Strength
If filters are connected without additional support structures, then assembly is simpler, but structural integrity and support between filters is insufficient
Solution Approach 1:
The support structure is merged with the filter frame itself rather than being a separate component. Corner members are formed as integral L-shaped structures that serve both as frame connectors and as support elements. Support members with engagement tabs are integrated into the frame assembly, providing structural reinforcement while maintaining a unified, relatively simple overall structure that does not require additional separate support components.
3Stability of the object's composition
If filters are rigidly connected, then structural stability is improved, but airflow bypass between connected filters is more likely to occur
Solution Approach 1:
The filter media itself serves as a flexible sealing element between adjacent filter units. The pleated or folded filter media can deform to conform to the spacing and alignment of connected frames, creating a flexible seal that prevents airflow bypass while accommodating minor misalignments. This flexible sealing approach maintains structural stability through the frame connections while preventing harmful airflow bypass through the adaptable filter media seal.
Data Source
AI summary
A system for air filtration having a plurality of interlocking filters for use in an HVAC system or other air filtration systems. Each interlocking filter can have a pleated filter media, a first frame, a second frame for supporting the first frame, an adhesive to connecting the pleated filter media to the first frame and the first frame to the second frame, and a one piece non-rigid flexible integral locking mechanism for connecting together the interlocking filters without clips or glue in a quick connect and quick disconnect manner.