Panel filter and method for manufacturing the same
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Solution Overview
Problem
Conventional panel filters in HVAC systems suffer from reduced airflow and efficiency due to mechanical seals that create impermeable areas, leading to decreased particulate capture and potential system damage from bowing and contact with internal components.
Innovation Solution
A panel filter design featuring a first air-permeable and particulate-impermeable media layer, a support grid, and a second air-permeable media layer coupled using an adhesive layer, eliminating the need for mechanical seals and enhancing airflow and particulate capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical seals (RF, ultrasonic, thermal welding) are used to seal edges and interior locations of panel filter media layers, then structural integrity and prevention of bowing is improved, but air permeability and particulate capture area are reduced due to creation of impermeable sealed regions
Solution Approach 1:
The patent removes the harmful mechanical seal elements from the interior of the filter panel, extracting only the necessary support function while eliminating the air-blocking sealed regions that reduce particulate capture area
Solution Approach 2:
The support grid provides localized structural reinforcement at specific points where support is needed, rather than creating widespread impermeable sealed regions across the entire filter surface, thus maintaining air permeability in most areas
2Stability of the object's composition
If mechanical seals are used to seal media layers, then prevention of bowing and structural stability is improved, but manufacturing complexity and equipment requirements increase
Solution Approach 1:
The patent replaces complex mechanical sealing systems (RF welding, ultrasonic welding, thermal welding equipment) with a simpler adhesive bonding system that uses common adhesives applied by conventional coating or spraying methods, significantly reducing manufacturing equipment complexity
Solution Approach 2:
The invention changes the bonding mechanism from high-energy mechanical sealing processes to low-energy adhesive bonding, altering the manufacturing parameters from requiring specialized welding equipment to using standard adhesive application equipment
3Strength
If mechanical seals create impermeable regions in panel filter, then structural support is improved, but airflow and heat exchange efficiency are reduced
Solution Approach 1:
The support grid provides localized structural support at discrete points rather than creating continuous impermeable sealed regions, allowing air and heat to flow through the majority of the filter surface area, thus maintaining heat exchange efficiency while providing necessary structural support
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 improves airflow and particulate capture efficiency, reduces the risk of filter bowing and damage, and simplifies the manufacturing process by eliminating the need for manual or specialized equipment, allowing for custom-sized filters with increased surface area for air passage.
Implementation Method 1
An adhesive layer is between the first media layer and the second media layer. The adhesive layer is configured to adhesively couple the first media layer to the second media layer.
Data Source
AI summary
A panel filter includes a first media layer constructed from a first material that is permeable to air and impermeable to particulates of a targeted size or type, a support grid, and a second media layer constructed from a second material that is permeable to air. The second media layer is adhesively coupled to the first media layer without a mechanical seal. When the first media layer and second media layer are coupled, the support grid is retained between the first media layer and the second media layer.