Interlocking Air Cleaner Filter Panels for Rigid 3D Filtration
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Solution Overview
Problem
Prior art air cleaners face issues with stand-alone filters that are not sufficiently rigid, leading to flexing and air leakage under strong airflow, and have limited surface area for airflow, resulting in increased power consumption and susceptibility to clogging.
Innovation Solution
A filter system with a frame and interlocking filter panels that resist deformation and securely fit within the air cleaner, providing a three-dimensional configuration with increased surface area for airflow, allowing for efficient filtration and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a stand-alone filter is used, then the filter can be easily installed, but it is not sufficiently rigid and flexes under strong airflow
Solution Approach 1:
The filter assembly is divided into multiple filter panels that can be separately installed into the frame, allowing for easy installation while maintaining structural rigidity through the distributed panel configuration
Solution Approach 2:
A frame structure acts as an intermediary between the filter panels and the air cleaner housing, providing rigid support to the filter panels while allowing for easy installation and removal of the entire assembly
2Ease of operation
If a stand-alone filter is used, then the filter can be easily installed, but air leaks around the edges of the filter
Solution Approach 1:
The frame structure merges the filter panels into a unified assembly that fits within the air cleaner housing, creating a sealed configuration that prevents air leakage while maintaining ease of installation through the integrated design
3Device complexity
If a flat filter panel is used, then the device structure is simple, but the surface area for airflow is limited
Solution Approach 1:
The filter assembly transitions from a single flat panel to a three-dimensional configuration with multiple panels arranged at different orientations, significantly increasing the total filter surface area while maintaining relatively simple individual panel structures
4Device complexity
If a flat filter panel is used, then the device structure is simple, but the filter is more susceptible to clogging
Solution Approach 1:
The three-dimensional arrangement of multiple filter panels increases the total surface area available for filtration, distributing the airflow more effectively and reducing the likelihood of clogging while keeping individual panel structures simple
5Device complexity
If a flat filter panel is used, then the device structure is simple, but increased power is required to generate airflow
Solution Approach 1:
The multi-panel three-dimensional configuration increases the total filter surface area, reducing airflow resistance and allowing the air moving device to operate at lower power levels while maintaining the simplicity of individual panel designs
Data Source
AI summary
A filter system for an air cleaner is provided according to an embodiment of the invention. The filter system includes a filter frame adapted to fit within the air cleaner and a filter assembly configured to fit to the frame. The filter assembly includes a top aperture and one or more filter panels. A filter panel of the one or more filter panels includes one or more panel edges and one or more interlocking tabs formed on the one or more panel edges.