Stackable Air Filter with Sensor Frame
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Solution Overview
Problem
The increasing adoption of thicker air filters in HVAC systems, while offering more surface area and reduced maintenance, comes at a higher cost and requires more energy to move air, necessitating a cost-effective and efficient solution for filtering and monitoring.
Innovation Solution
A stackable air filter system with standardized, pleated filter elements and a reusable frame that includes sensors and communication modules, allowing for easy replacement and monitoring, reducing material usage and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If thicker filter elements (3-5 inches) are used to increase surface area and reduce maintenance frequency, then maintenance duration is improved, but manufacturing cost and energy consumption increase
Solution Approach 1:
The filter system is divided into a reusable frame and disposable filter elements. The frame contains sensors and electronics, while the filter elements can be easily replaced. This segmentation allows the expensive frame to be retained while replacing only the consumable filter media, reducing overall system cost and energy consumption compared to replacing entire thick filters every 6-12 months.
Solution Approach 2:
The patent changes the parameter of filter thickness by providing multiple filter element thicknesses (1 inch, 2 inches, 3 inches, 4 inches, 5 inches) that can be selected based on specific application requirements. This allows optimization between surface area, air resistance, and energy consumption rather than universally adopting the thickest option.
2Duration of action of stationary object
If thicker filter elements (3-5 inches) are used to increase surface area and reduce maintenance frequency, then maintenance duration is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the filter into a reusable frame and disposable elements, the manufacturing cost is reduced. The frame, which contains expensive sensors and electronics, is manufactured once and reused. Only the relatively inexpensive filter elements need to be manufactured and replaced periodically, significantly lowering the overall manufacturing cost compared to producing complete thick filters for every replacement cycle.
Solution Approach 2:
The filter elements are designed as disposable components that are replaced every 6-12 months, while the expensive frame with sensors is retained. This approach uses cheap, short-living filter media to filter air continuously, while the investment in the reusable frame is amortized over multiple replacement cycles, reducing the effective cost per unit time.
3Volume of moving object
If standardized pleated filter elements with cutouts are used to enable stacking and compact storage, then storage volume is reduced, but filter element complexity increases
Solution Approach 1:
The filter system is segmented into standardized pleated filter elements with specific cutouts that enable them to stack compactly. The cutouts are positioned to allow the pleats of adjacent filter elements to interlock during stacking, creating a space-efficient storage configuration. This segmentation allows for standardized manufacturing and easy assembly while minimizing storage volume.
Solution Approach 2:
The pleated filter elements are designed to nest within each other when stacked, with the cutouts allowing the pleats of one element to fit into the grooves of another. This nesting arrangement significantly reduces the storage volume required for multiple filter elements, making compact storage and shipping feasible without requiring additional packaging materials or space.
4Object-generated harmful factors
If edges of filter elements engage with the filter frame to create an airtight seal, then air leakage is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The filter frame incorporates flexible sealing elements (such as gaskets or elastomeric seals) that can deform to accommodate minor variations in filter element dimensions. These flexible seals engage with the filter element edges to create an airtight barrier while tolerating manufacturing tolerances. The flexibility allows the seal to conform to the actual geometry of the filter element, ensuring effective sealing without requiring extremely tight manufacturing precision.
Solution Approach 2:
The sealing design includes built-in compensation for manufacturing variations through the use of flexible seal materials and geometric features that allow for slight misalignments. The seal engagement mechanism is designed with inherent tolerance, where the flexible material can compress or deform to maintain sealing effectiveness even when dimensional tolerances are not extremely tight, thereby cushioning against the impact of normal manufacturing variations.
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 system reduces manufacturing and shipping costs, simplifies installation and maintenance, and provides efficient air filtration with reduced energy consumption while enabling effective air quality monitoring and data collection.
Implementation Method 1
The cutout is configured to be aligned with a magnetic closure system of the filter frame
Implementation Method 2
The cutout is configured to be aligned with an opening of a differential pressure sensor system of the filter frame
Data Source
AI summary
The current application relates to an air filter that reduces the cost of air-filters by separating the filter element into multiple stackable and disposable sections of a same standardized shape and size. The filter elements may be inserted into a unique, reusable filter frame that includes sensors and communication capability. The filter sections and the frame are made such that the filter sections inserted into the frame to align to and fit into each of the uniform frame sections securely and without air leakage. Shipping and storing the filter sections are made easy by size and shape standardization, enabling them to be stacked one on top of the other so that the filter folds fit into each other as they are stacked, making shipping and storing economical. The frame itself is made from hard plastic and the sensors and communication module are attached to the frame.