Modular Air Filter Housing for Paint Particulate Collection
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Solution Overview
Problem
Current air filtration systems for paint particulates are inefficient due to premature clogging, cumbersome assembly, and the need for large, heavy filters that require multiple workers for replacement, leading to increased complexity and waste.
Innovation Solution
A modular filter support frame with interchangeable components, including a plurality of air filter boxes, a removable tray, and a plenum, made from disposable corrugated material, which simplifies assembly and replacement by channeling air and particulates through multiple filter boxes simultaneously, reducing waste and physical demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large filter assembly is used to capture harmful fumes and particulates, then the filtration capacity is improved, but the weight and complexity increase making it difficult to replace
Solution Approach 1:
The filter assembly is divided into multiple individual filter boxes that can be handled separately. Each filter box contains a portion of the total filter media, allowing the large filtration capacity to be achieved through aggregation of multiple smaller, manageable units rather than one large heavy assembly.
Solution Approach 2:
The filter media is folded into a compact box configuration rather than using a flat or expanded layout. This dimensional transformation allows the same filtration surface area to be contained in a smaller, lighter package that is easier to handle and replace.
2Ease of manufacture
If cardboard baffles or shredded paper are used as filter media, then the filter can be easily manufactured, but the entrance clogs prematurely reducing filter media utilization
Solution Approach 1:
The filter media combines shredded paper or cardboard with a binding agent to create a composite material with optimized properties. This composite structure maintains the ease of manufacture from paper/cardboard while preventing premature clogging through the bound configuration that allows better airflow distribution across the entire filter media surface.
3Reliability
If a large filter assembly is used to ensure adequate filtration, then the filtration effectiveness is improved, but the assembly becomes cumbersome to assemble and maintain
Solution Approach 1:
The filter system is segmented into multiple identical or interchangeable filter boxes that can be assembled in a modular fashion. This segmentation reduces assembly complexity by allowing standardized components to be quickly installed and replaced without handling a single large complex assembly.
Solution Approach 2:
The filter boxes are designed as universal, interchangeable units that can be positioned in various locations within the filter assembly. This universality simplifies maintenance and assembly by allowing any filter box to be removed and replaced with another, reducing the need for complex disassembly procedures.
4Reliability
If multiple workers and lifting equipment are used to replace the filter assembly, then the heavy filter can be replaced, but the time and cost increase
Solution Approach 1:
By dividing the filter system into multiple smaller filter boxes, each unit can be handled by a single worker without requiring lifting equipment. This segmentation directly reduces the time and resources needed for replacement while maintaining the overall filtration function through the collective capacity of all filter boxes.
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
The modular design enhances the efficiency of air filtration by allowing simultaneous processing of air and particulates, reducing waste and physical strain, while enabling easier assembly and replacement of filter components, thus improving the overall filtration process.
Implementation Method 1
filter media placed inside of the filter box to capture paint particulates and allow filtered air to exit
Data Source
AI summary
The disclosed technology relates to air filters and filter assemblies for filtering particulates from air, and more particularly to for filtering paint particulates from air. The disclosed technology can include a filter support frame having a plurality of air filter receptacle shelves configured to support a plurality of air filter boxes, a tray receptacle configured to receive a removable tray, an inlet configured to receive a mixture of air and particulates and channel a mixture of air and particulates across the removable tray toward the plurality of air filter boxes, an outlet configured to receive filtered air from the plurality of air filter boxes and channel the filtered air out of the filter support frame, and a base configured to support a removable plenum. The removable tray can be configured to collect particulates.