Interlocking HVAC Filter Bank with Integral Locking Mechanism
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Solution Overview
Problem
There is a need for a method to quickly assemble interlocking filters into a non-deforming particulate filtration bank that provides 95% particulate filtration, is adaptable to various sizes and shapes, and prevents airflow bypass in heating, ventilation, and air conditioning systems, while minimizing maintenance time and ensuring compatibility with different equipment configurations.
Innovation Solution
The method involves creating a non-deforming particulate filtration bank using interlocking filters with a one piece non-rigid flexible integral locking mechanism, which connects without adhesive or clips, allowing for quick connect and quick disconnect functionality, and uses pleated filter media with antimicrobial or carbon coatings, supported by frames that can be made from various materials and customized shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional filtration banks are used, then air filtration is provided, but assembly time is excessive and customization to various sizes and shapes is difficult
Solution Approach 1:
The filtration bank is divided into multiple individual filter units that can be assembled together like building blocks. Each filter unit has standardized connection features (protrusions and recesses) that enable quick assembly while allowing the overall bank to be customized in size and shape by varying the number and arrangement of units.
Solution Approach 2:
The filter units are designed with universal connection features that work across all units regardless of size or shape variations. The same protrusion-recess connection mechanism is used for all filters, enabling both quick assembly and adaptability to different configurations through a single standardized interface design.
2Ease of operation
If filters are connected without proper support, then assembly is simple, but the filtration bank deforms and allows airflow bypass
Solution Approach 1:
The support structure is merged with the filter units themselves rather than being a separate component. Rigid support elements are integrated into the frame or housing of each filter unit, providing structural reinforcement while maintaining the simplicity of the assembly process. The support features are built-in and become part of the connection interface.
Solution Approach 2:
The filter units combine rigid support structures with flexible sealing elements to create a composite assembly that is both structurally sound and easily assembled. The rigid portions provide deformation resistance while flexible sealing components ensure airflow tightness, and the combination allows for simple snap-together assembly without complex fastening mechanisms.
3Strength
If adhesive or clips are used to connect filters, then connection strength is improved, but assembly time increases and quick disconnect becomes difficult
Solution Approach 1:
The connection system replaces adhesive bonding and clip fastening with a mechanical interlocking mechanism using protrusions and recesses. This allows filters to be connected strongly through friction and geometric interlocking without requiring chemicals or separate fasteners, enabling both strong connections and quick assembly/disassembly.
Solution Approach 2:
The protrusion-recess connection features are self-aligning and self-locking, requiring no additional tools, adhesives, or fastening operations. The filters automatically form a strong connection when brought together, and can be easily separated by overcoming the friction lock, enabling maintenance personnel to perform assembly and disassembly quickly without specialized equipment or materials.
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
This solution enables efficient, adaptable, and cost-effective air filtration with high particulate capture rates, reducing maintenance costs and ensuring compatibility with diverse HVAC systems, while maintaining air integrity and preventing damage to equipment.
Implementation Method 1
through which air only passes through filter media, that is adaptable in the field to various sizes and shapes, and provides 95 percent particulate filtration
Implementation Method 2
uses pleated filter media with antimicrobial or carbon coatings
Implementation Method 3
uses pleated filter media with antimicrobial or carbon coatings
Data Source
AI summary
A method for air filtration having a plurality of interlocking filters for use in an HVAC system or in 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.