Truncated Pyramidal Air Filter Frame for Lower Pressure Drop
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Solution Overview
Problem
Current air filters with high efficiency face limitations in increasing media area within standard 1 or 2 inch depths, leading to air flow restrictions and high energy consumption, as well as potential bridging issues that affect performance.
Innovation Solution
A deep pleated air filter assembly with a truncated pyramidal frame design that increases media area while maintaining standard installation compatibility, using materials like paper, metal, or plastic, and providing a positive seal to reduce air bypass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If more filter media area is added to increase air flow and reduce pressure drop, then air flow efficiency improves, but the filter depth limitation of standard 1 or 2 inch grills prevents further media area increase
Solution Approach 1:
The filter frame transitions from a traditional flat rectangular shape to a three-dimensional truncated pyramidal shape with inwardly angled side walls. This dimensional change allows the filter media to be arranged in a deeper, angled configuration that increases the effective media area within the same grill footprint, thereby improving air flow efficiency without requiring deeper grill installation.
Solution Approach 2:
The filter frame is divided into multiple angled side walls that create distinct pleated media sections. Each side wall segment contributes to the overall media area while maintaining structural integrity. This segmentation allows the media to be distributed across multiple angled surfaces, maximizing the total filtering area within the constrained depth of standard grills.
2Ease of operation
If standard rectangular filter frames are used, then installation in existing grills is simple, but the media area is limited and air flow restriction occurs
Solution Approach 1:
The truncated pyramidal filter frame is designed to be universally compatible with standard rectangular grill openings while providing enhanced three-dimensional media configuration. The frame maintains external dimensions that fit existing grills but creates internal angled spaces that maximize media area, achieving both ease of installation and improved air flow capacity.
3Reliability
If high efficiency filter media is used, then filtration performance improves, but more media area is required which increases pressure drop and energy consumption
Solution Approach 1:
By transitioning to a three-dimensional truncated pyramidal configuration, the filter provides increased media area that allows high efficiency filtration media to be used without excessive pressure drop. The angled side walls create additional volumetric space for media arrangement, ensuring sufficient filtering surface area to maintain low resistance to air flow and reduce energy consumption.
Data Source
AI summary
A filter assembly is adapted for separating particulate matter entrained in a moving fluid stream. The filter assembly comprises a flow-through three dimensional filter frame including a plurality of joined side walls, and having first and second opposing open faces. The first open face defines a fluid inlet into which the moving fluid stream is drawn, and the second open face defines a fluid outlet from which the moving fluid stream passes. At least one of the joined side walls is inwardly angled from the first open face to the second open face, such that the fluid outlet is smaller than the fluid inlet. A filtration medium is supported within the filter frame, and extends between the joined side walls and from the first open face to the second open face.