Offset Slot Air Filter Frame for Stability
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Solution Overview
Problem
Existing air filters in forced air systems face challenges in maintaining structural stability during assembly and installation, leading to potential air leaks and instability, particularly due to the inherent resilience of materials like paperboard which can cause folded sections to unfold.
Innovation Solution
The design incorporates a frame with an open-ended, offset slot in the inner sidewall and an offset junction between the downstream flange and inner sidewall, along with a tab that extends between the inner and outer sidewalls, to create a self-stabilizing corner that minimizes the tendency of the frame to unfold during assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional framed air filters are assembled using conventional methods, then assembly is simple, but the frame lacks structural stability and folded sections tend to unfold
Solution Approach 1:
The frame is divided into multiple sections with distinct functional features: upstream flange, downstream flange, inner sidewall with offset slot, outer sidewall, and tab. This segmentation allows each component to serve a specific structural purpose, particularly the offset slot and tab combination that prevents unfolding while maintaining overall frame stability
Solution Approach 2:
The frame incorporates an asymmetric offset slot positioned at a specific location on the inner sidewall, creating an uneven distribution of structural support points. This asymmetric design provides inherent stability by preventing symmetric unfolding modes, as the offset slot creates a preferred folding path that maintains frame integrity
2Ease of manufacture
If the frame uses resilient materials like paperboard, then the material is easy to work with and cost-effective, but the folded sections have inherent resilience that causes them to unfold
Solution Approach 1:
The offset slot and tab are designed to create preliminary anti-action against the inherent resilience of the paperboard material. The tab extends into the offset slot to create a mechanical interlock that pre-counteracts the unfolding force generated by material resilience, preventing the folded sections from springing open during assembly and installation
Solution Approach 2:
The tab acts as an intermediary element between the inner sidewall (with offset slot) and outer sidewall, mediating the structural relationship between these components. This intermediary tab provides a controlled interaction point that manages the resilient forces in the paperboard, allowing the folded sections to remain stable without requiring additional fastening mechanisms
3Productivity
If the frame structure is simplified for easy assembly, then assembly efficiency increases, but air leaks may occur due to insufficient structural stability
Solution Approach 1:
The design merges multiple functions into the frame structure itself: the offset slot and tab combination simultaneously provides structural stability, prevents unfolding, and ensures proper sealing between frame sections. This integrated approach eliminates the need for separate stabilizing components, maintaining assembly efficiency while preventing air leaks through the enhanced structural integrity
Data Source
AI summary
A framed air filter and method of making. The framed air filter includes air filter media and a frame with a frame portion with an upstream flange and a downstream flange and an inner sidewall and an outer sidewall. The inner sidewall includes an open-ended, offset slot.