Pleated Disposable Air Filter Media With Collapsible Fold Crease
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Solution Overview
Problem
Existing air filters are not compressible, crushable, or foldable, leading to high shipping costs due to the need for large boxes and inflexible packaging, which also complicates disposal and replacement in HVAC systems.
Innovation Solution
A collapsible and foldable air filter media composed of modular filter strips with folding creases, allowing it to be folded into standard shipping envelopes or bags, reducing shipping costs and facilitating easy disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid cardboard frame and steel mesh structure is used, then filter strength and structural stability are improved, but compressibility and foldability are lost
Solution Approach 1:
The filter is divided into multiple flexible filter strips that can be folded independently, replacing the monolithic rigid frame structure. Each strip maintains sufficient strength through its construction while enabling overall compressibility when folded.
Solution Approach 2:
The rigid cardboard frame is replaced with flexible filter strips made of breathable material that can be folded and compressed. The strips maintain structural integrity during use but can be easily folded for storage and shipping.
2Reliability
If rigid packaging boxes are used to protect filters during transport, then filter protection is improved, but shipping cost and packaging volume increase
Solution Approach 1:
The filter strips are folded into a compact nested configuration that fits within standard shipping envelopes, eliminating the need for large rigid boxes. Multiple filters can be efficiently packaged together.
Solution Approach 2:
The filter transitions from a rigid static structure to a dynamic folded structure that adapts to packaging constraints. The filter can be compressed to minimal volume for shipping while maintaining protection during transport.
3Ease of manufacture
If non-pleated filter media is used, then manufacturing cost is reduced, but filtration surface area and efficiency are decreased
Solution Approach 1:
The filter media is segmented into multiple pleated folds that create additional surface area within the same planar footprint. This segmentation allows the filter to achieve high filtration area while maintaining cost-effective construction.
Solution Approach 2:
The filter strips are pleated to create three-dimensional folds that increase the effective filtration surface area. The pleats add vertical dimension to the filter media, maximizing surface area without increasing the filter's planar dimensions.
Data Source
AI summary
A foldable and disposable air filter media for insertion into an air filter frame is disclosed. The air filter media includes two or more filter pleated strips that are joined together. The outer edges of the air filter media are fixed to the frame to form the air filter. Each of the filter pleated strips have a number of pleats that increase the area to reduce pressure drop across the filter media while allowing air flow through to remove unwanted particles from the filtered air. A folding crease is formed between the opposite border edges of the air filter media allowing the air filter media to be folded for shipping or disposal.