Multi-Layered Pleated Filter Frame Assembly to Prevent Air Leaks
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Solution Overview
Problem
Existing filter devices face challenges such as unstable fixation of pre-filters and filter media, potential air leaks due to weak adhesive forces, and difficulties in manufacturing multi-layered pleated filters without gaps.
Innovation Solution
A method for manufacturing a filter unit with a rectangular filter section comprising overlapping filters with pleated shapes, supported by a frame with adhesive layers to ensure stable fixation and integration of multiple layers without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the pre-filter and filter media are fixed only at the top and bottom, then the number of parts is reduced, but the fixation becomes unstable
Solution Approach 1:
The frame is divided into multiple segments (first frame, second frame, third frame) that collectively provide support at multiple locations. Each frame segment fixes specific portions of the filter assembly, distributing the fixation points throughout the structure rather than concentrating them at only two locations, thereby achieving stable fixation without excessive complexity
Solution Approach 2:
The fixation approach transitions from one-dimensional (top and bottom only) to three-dimensional distribution, with frames positioned at upstream, downstream, and lateral locations. This spatial distribution of fixation points across multiple dimensions provides enhanced stability while maintaining a manageable number of components
2Weight of moving object
If the pre-filter and filter pack are partially fixed to the frame, then weight is reduced and replacement is easier, but adhesive force becomes weak causing air leaks
Solution Approach 1:
Different regions of the filter assembly are fixed with different degrees of adhesion strength. The first frame provides strong fixation at the upstream end where sealing is critical, while the second and third frames provide support at other locations. This localized variation in fixation quality ensures seal integrity at critical points while maintaining overall lightweight construction
Solution Approach 2:
Instead of providing uniform partial fixation throughout, the invention applies excessive adhesive action at specific critical locations (upstream end with first frame) where seal integrity is most important, while using lighter fixation elsewhere. This targeted approach ensures reliability where needed without the weight penalty of uniform heavy fixation
3Reliability
If multiple pleated filters are stacked to provide high filtration performance, then filtration efficiency is improved, but manufacturing becomes difficult due to gaps and alignment issues
Solution Approach 1:
Adhesive materials serve as intermediaries between the pleated filters and the frame structure. The adhesive fills and compensates for gaps that naturally occur when stacking pleated filters, allowing multiple filters to be securely bound together without requiring perfect alignment or gap-free contact, thereby simplifying the manufacturing process while maintaining filtration performance
Solution Approach 2:
The invention changes the physical state and properties of the bonding interface by using adhesive materials that can flow and conform to the pleated filter surfaces. This parameter change from rigid mechanical contact to flexible adhesive bonding allows for easier assembly of multiple pleated filters with acceptable tolerances, reducing manufacturing difficulty while ensuring secure fixation
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 solution provides a stable and secure fixation of multi-layered filters, preventing air leaks and ensuring effective filtration performance while simplifying the manufacturing process for pleated filters.
Implementation Method 1
a pair of first frames (41) having a first adhesive layer (41A) to which the filter section (3) is fixed; and a pair of second frames (42) having a second adhesive layer (42A) to which the filter section (3) is fixed
Data Source
AI summary
The filter unit includes a filter section having a first filter and a second filter being of a pleated shape, and a frame having a pair of first frames and a pair of second frames having an adhesive layer. The filter unit is manufactured by stacking the first filter on the second filter, arranging a first support member opposite to the first frame with respect to a first fixed portion, arranging a second support member for supporting the second fixed portion opposite to the first frame with respect to the second fixed portion, fixing the first frame to the first fixed portion and the second fixed portion, and fixing the first frame to the second frame.