Nestable Pleated Air Filter Bridging Filaments
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Solution Overview
Problem
Framed pleated air filters used in HVAC systems face challenges in withstanding forces from forced-air flow without a support frame, leading to deformation or collapse, and existing solutions do not allow for efficient nesting and storage due to self-supporting issues.
Innovation Solution
A nestable framed pleated air filter design featuring non-self-supporting, compressible pleated media with bridging filaments bonded to upstream pleat tips and a support frame, allowing for efficient nesting and airflow stabilization without becoming self-supporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If framed pleated air filters use non-self-supporting compressible pleated media, then the filters become nestable for efficient storage and shipping, but the filters cannot withstand forces from forced-air flow without a support frame
Solution Approach 1:
The filter media is segmented into multiple pleats with bridging filaments connecting them, allowing the media to be compressible for nesting while maintaining structural integrity during operation. The segmentation creates individual pleat units that can compress independently yet remain connected through bridging filaments.
Solution Approach 2:
The filter design enables nested storage by allowing multiple filters to be stacked together in a compact arrangement. The non-self-supporting compressible media allows the filters to be compressed into each other for storage and shipping, reducing space requirements while maintaining functionality when installed.
2Strength
If framed pleated air filters use self-supporting pleated media, then the filters can withstand forces from forced-air flow without a support frame, but the filters cannot be efficiently nested and stored
Solution Approach 1:
The filter media transitions from a rigid self-supporting state during operation to a compressible state for storage. The bridging filaments and frame structure provide dynamic support during airflow operation, while the same structure allows compression for nesting when not in use, enabling the media to adapt between operational and storage states.
3Reliability
If bridging filaments are bonded to upstream pleat tips, then airflow efficiency is maintained and pleats are stabilized, but manufacturing complexity increases
Solution Approach 1:
The bridging filaments are bonded to the upstream pleat tips during the manufacturing process before the filter is put into service. This preliminary bonding action stabilizes the pleat structure and ensures optimal airflow characteristics are established from the start, preventing pleat deformation that would reduce efficiency during operation.
Data Source
AI summary
A nestable framed pleated air filter, including a non-self-supporting, compressible, pleated air filter media with a plurality of oppositely-facing pleats and with a plurality of upstream pleat tips and downstream pleat tips and downstream pleat valleys, the pleated air filter media further including a plurality of bridging filaments that are bonded to at least some of the upstream pleat tips. The filter includes a frame with sidewalls that are angled so that the framed pleated air filter is nestable.