Reusable Filter Frame with Overlapping Sidewalls
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Solution Overview
Problem
The high cost and waste associated with replacing entire air filters due to decreased filtering performance over time, necessitate a solution for reusable filter frames that allow for media replacement while maintaining efficiency and reducing fabrication costs.
Innovation Solution
A filter frame design comprising two frame sections with overlapping sidewalls and a locking mechanism using detents and detent openings, allowing for easy assembly and disassembly, enabling the replacement of filter media without fully replacing the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire air filter is replaced when filtering performance decreases, then filtering performance is maintained, but waste increases and replacement cost increases
Solution Approach 1:
The air filter is divided into two separable components: a reusable frame structure and a replaceable filter media. The frame maintains its structural integrity and filtering geometry across multiple cycles, while only the saturated media is discarded. This segmentation allows the expensive frame to be retained and reused, significantly reducing waste and replacement costs while maintaining filtering performance.
Solution Approach 2:
The invention enables recovery and reuse of the frame component after the filter media becomes saturated. The frame is designed to be disassembled from the media, cleaned or reused directly, thereby recovering the valuable structural component rather than discarding the entire filter assembly. This recovering process reduces material waste and lowers long-term replacement costs.
2Reliability
If the entire air filter is replaced when filtering performance decreases, then filtering performance is maintained, but replacement cost increases
Solution Approach 1:
By segmenting the filter into a durable frame and consumable media, the system reduces replacement costs. The frame, which represents the majority of the initial cost, is retained and reused across multiple filter media cycles. Only the relatively inexpensive media needs to be replaced, significantly reducing the overall replacement cost while maintaining filtering performance.
Solution Approach 2:
The frame is recovered and reused instead of being discarded with the saturated media. This recovery mechanism reduces the frequency and cost of replacements, as the expensive frame structure is maintained across multiple service cycles, thereby lowering the overall replacement cost while ensuring continuous filtering performance.
3Loss of substance
If filter media is replaced within existing frame, then waste decreases and cost decreases, but assembly and disassembly complexity increases
Solution Approach 1:
The filter system is segmented into a frame and media that can be easily separated. The frame maintains a consistent structural design with standardized interfaces, allowing the media to be quickly inserted and removed without complex manipulation. This segmentation simplifies the replacement process despite the added complexity of the separable design.
Solution Approach 2:
The frame is designed with dynamic assembly and disassembly capabilities, allowing easy separation and recombination of the frame and media components. The interface design enables straightforward attachment and detachment operations, making the replacement process user-friendly and not significantly more complex than replacing a traditional entire-filter unit.
4Reliability
If overlapping sidewalls are used in frame sections, then air flow bypass is reduced, but manufacturing complexity increases
Solution Approach 1:
The sidewalls of adjacent frame sections are designed to overlap and merge into a unified structure. This merging of sidewalls eliminates gaps and interfaces that could allow air flow bypass, ensuring that all air passes through the filter media. The overlapping design is integrated into the molding process, and while it adds some manufacturing complexity, it is achieved through standardized components and assembly procedures.
Data Source
AI summary
A filter frame that may be reusable with filler media replacements. The filter frame may include a frame section have a first sidewall and a second sidewall along the outer periphery. The first sidewall may be at a lager perimeter than the second sidewall. A locking mechanism may releasably secure two frame sections together. The filter frame may include a filter media contained between two frame sections.