Modular HVAC Filter Frame for Contamination-Free Media Replacement
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Solution Overview
Problem
Conventional HVAC filters are prone to damage, contamination, and inefficient disposal due to their flimsy design and semi-rigid construction, which complicates maintenance and handling, and they do not survive moisture exposure effectively.
Innovation Solution
A modular filter frame system with two parts that can be easily opened and closed using clips, allowing for the replacement of filter media without disturbing the existing media, enabling flexible handling and disposal of soiled media while maintaining filter performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional HVAC filters use a light cardstock frame with glued filter media, then the filter is inexpensive and simple to manufacture, but the filter is flimsy, prone to crushing and distortion, and difficult to handle without contamination
Solution Approach 1:
The filter is divided into separate components: a rigid frame structure and a removable filter media panel. This segmentation allows the frame to provide structural support while the media can be easily removed and replaced without handling the entire filter assembly, reducing contamination risk and improving handling convenience.
Solution Approach 2:
The filter media is extracted as a separate removable panel from the frame. The media panel can be taken out for disposal or replacement without disturbing the frame structure, enabling clean and efficient maintenance while maintaining the integrity of the remaining filter components.
2Shape
If conventional HVAC filters use a semi-rigid construction, then the filter maintains its shape, but the filter is likely to contaminate the home interior if handled roughly when changed
Solution Approach 1:
By separating the filter into a rigid frame and a removable media panel, the frame maintains structural integrity and shape while the media panel can be handled separately. This allows the media to be removed without compromising the frame's structural support, reducing the risk of contamination during handling.
Solution Approach 2:
The filter media is designed as a flexible panel that can be easily removed and disposed of. This flexible design allows the media to be handled separately from the rigid frame, enabling clean removal without disturbing the frame structure that maintains the filter's overall shape and integrity.
3Ease of operation
If conventional HVAC filters are designed for convenience, then the filter is easy to install, but the filter does not survive moisture exposure and is subject to damage in shipment and storage
Solution Approach 1:
The filter is segmented into a durable rigid frame and a removable media panel. The frame can be stored and shipped separately from the media, protecting both components from damage. The frame's robust construction survives moisture exposure and handling, while the media can be replaced as needed, maintaining installation convenience.
Solution Approach 2:
The rigid frame structure provides protective support for the filter media during storage and shipment. The frame acts as a protective enclosure that cushions the media from damage, while still allowing for convenient installation by simply attaching the media panel to the frame at the installation location.
4Device complexity
If conventional HVAC filters use a integrated design, then the filter is simple in structure, but the filter requires complete replacement when media needs changing, increasing cost and waste
Solution Approach 1:
The filter is segmented into a reusable rigid frame and a disposable media panel. This segmentation allows only the media panel to be replaced when it becomes soiled, while the frame remains in service. This reduces maintenance costs and waste compared to replacing the entire integrated filter, while the structural simplicity of the frame-media assembly is maintained.
Solution Approach 2:
The filter media panel is designed to be discarded after use, while the rigid frame is recovered and reused for subsequent media panels. This approach reduces the need to manufacture entirely new filters for each replacement, lowering maintenance costs and reducing waste, while maintaining a simple overall structure.
Data Source
AI summary
The present disclosure provides methods and apparatus for user customizable configurations and replacement of a heating, ventilation and air conditioning filter media and frames. A filter media may be combined with a media frame according to user specifications. One filter media or combinations of multiple filter media may be chosen by a user to create custom filter configurations. Filter media may be separated from the media frame and disposed of in a manner generally more convenient than traditional HVAC filter replacement.