Multi-Panel Air Filter Holding Assembly for Fluid Bypass Control
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Solution Overview
Problem
Existing filter elements with multiple panels of filter media face challenges in maintaining efficient fluid flow and structural integrity, particularly when configured for inside-out or outside-in fluid flow, leading to potential bypass and reduced filtration effectiveness.
Innovation Solution
A multi-component holding assembly comprising a support frame, base frame, end cap structures, and a second side support structure, which maintains angled filter media panels to form a wedge-shaped cavity, ensures secure attachment, and uses adhesive and seal materials to prevent fluid bypass, while allowing for easy handling and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple panels of filter media are configured for inside-out or outside-in fluid flow, then filtration coverage is improved, but fluid bypass occurs and filtration effectiveness is reduced
Solution Approach 1:
The filter element is divided into multiple panels of filter media (first panel, second panel, third panel, fourth panel) arranged in a multi-panel configuration. Each panel is separately mounted to the support frame and sealed independently, allowing the system to maintain filtration coverage across multiple sections while preventing bypass through proper sealing of each segment.
Solution Approach 2:
A seal material is introduced as an intermediary element between the filter panels and the support frame/end caps. This seal material (adhesive or mechanical seal) prevents fluid bypass by creating a barrier that directs fluid flow through the filter media panels while maintaining the structural integrity of the assembly.
2Quantity of substance
If multiple panels are mounted to form a cavity, then filtration surface area is increased, but structural integrity is compromised
Solution Approach 1:
The support frame is segmented into multiple components (first support frame portion, second support frame portion, third support frame portion, fourth support frame portion) that can be independently manufactured and assembled. Each segment is specifically designed to mount a corresponding filter panel, distributing the structural load and maintaining integrity while accommodating multiple panels for increased filtration surface area.
Solution Approach 2:
Multiple discrete components (support frame portions, end caps, seal materials) are merged into a single integrated assembly through adhesive bonding and mechanical interlocking. This merging process creates a structurally sound unit that can withstand operational stresses while maintaining the multi-panel configuration for increased filtration capacity.
3Productivity
If panels are sealed on three sides to form a cavity, then fluid flow control is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing system is segmented into discrete seal locations (first seal, second seal, third seal) corresponding to the three sides of each panel cavity. Each seal can be applied independently during assembly, simplifying the manufacturing process while maintaining effective fluid flow control through proper sealing of each segment.
Solution Approach 2:
A seal material serves as an intermediary element that simplifies the sealing process. Instead of requiring complex sealing mechanisms for each side, the seal material (adhesive or mechanical seal) provides a straightforward method to create effective seals at the critical interfaces between panels and support frame, reducing manufacturing complexity while ensuring proper fluid flow control.
4Ease of repair
If a multi-component holding assembly is used, then ease of replacement is improved, but device complexity increases
Solution Approach 1:
The filter element is segmented into modular components (panels, support frame portions, end caps) that can be independently handled and assembled. This segmentation allows the entire assembly to be easily replaced as a unit while simplifying the individual components for manufacturing and maintenance, reducing the practical impact of increased device complexity.
Solution Approach 2:
The support frame and end cap structures serve multiple functions: they provide structural support, maintain panel positioning, create sealing surfaces, and facilitate assembly/disassembly. This multi-functionality reduces the need for additional specialized components, thereby limiting the increase in device complexity while maximizing ease of replacement through standardized interfaces.
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 enhances fluid flow efficiency, maintains structural integrity, and facilitates easy maintenance by ensuring secure attachment and sealing, thereby improving filtration performance and ease of replacement.
Implementation Method 1
the first and second end cap structures are composite structures including a cupped end cap and adhesive within the cupped end cap. At least the adhesive captures the corresponding side of the support frame, portion of the base frame and sealing the corresponding sides of the first and second filter media panel
Implementation Method 2
a seal material is interposed between the second side of the support frame and the second side support structure. The seal material seals the second side of the first and second filter media panels to at least one of the second side of the support frame and the second side support structure
Data Source
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AI summary
A filter element and multi-component holding assembly for a filter element is provided. The filter element includes first and second media panels, a support frame, a base frame and first and second end cap structures. Each filter media panel defines first, second, third and fourth sides. The first and second sides extend between the third and fourth sides. The support frame maintains the first and second filter media panels in a spaced orientation forming a cavity therebetween. The base frame defines a first opening in fluid communication with the cavity. The first end cap structure seals the third side of the first and second filter media panels and the second end cap structure seals the fourth side of the first and second filter media panels. The base frame has a first portion captured in the first end cap structure and a second portion captured in the second end cap structure.