Flexible Wire-Frame Filter Element for Tight Housing Installation
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Solution Overview
Problem
Existing HVAC systems face challenges with rigid filter elements that require frequent replacement, lead to contaminated airflow, and are prone to damage due to limited access and environmental concerns, especially in spaces like supermarket refrigeration units.
Innovation Solution
A flexible filter element is fabricated on-site using wire frames attached with spring connectors, allowing for custom size adjustment and easy assembly, with end-caps for protection during handling and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid filter elements with cardboard superstructure are used, then structural support is provided, but rigidity deteriorates during high humidity conditions or rainstorms causing the filter to be drawn out of the housing
Solution Approach 1:
The patent changes the material parameter from cardboard to wire frame structure. The wire frame maintains structural support while being impervious to humidity and rain, eliminating the deterioration problem that causes filters to be drawn into the fan.
Solution Approach 2:
The patent uses a composite structure combining wire frame with filter media and end-caps. This composite design provides both structural integrity and environmental resistance, solving the reliability issue in humid conditions.
2Ease of manufacture
If standard sized filter elements are used, then manufacturing is simplified, but significant contaminated airflow circulates around the filter elements due to tolerance variations
Solution Approach 1:
The patent divides the filter element into modular segments with adjustable sizing. The filter media and wire frame can be cut to custom lengths to match the specific housing dimensions, eliminating the air leakage problem caused by tolerance variations while maintaining manufacturing simplicity.
Solution Approach 2:
The patent introduces adjustable and customizable dimensions to the filter element design. This dynamic adaptation to specific housing sizes ensures optimal sealing and eliminates contaminated airflow circulation.
3Length of moving object
If long filter elements are used in supermarket refrigeration units, then filtration coverage is improved, but access to the filter housing is limited making replacement difficult
Solution Approach 1:
The patent segments the long filter element into manageable sections or provides a design that can be partially removed. This allows technicians to access and replace filters in locations with limited space, maintaining both length for coverage and ease of operation.
Solution Approach 2:
The patent may employ flexible or collapsible filter element designs that can be compressed or folded to fit through limited access points, then expanded to full length within the housing, solving both the length and accessibility contradiction.
4Strength
If wire frames are rigidly fastened together, then structural integrity is maintained, but the filter unit cannot be inserted into tight spaces without moving equipment
Solution Approach 1:
The patent uses flexible connectors instead of rigid fastening methods. The wire frames can bend or flex during installation to navigate tight spaces, then maintain structural integrity when installed. This dynamic flexibility resolves the contradiction between strength and ease of operation.
Solution Approach 2:
The patent employs flexible wire frame constructions that can deform during installation and return to their rigid configuration when installed, providing both structural integrity and installation flexibility.
Data Source
AI summary
An air filter element partially-fabricated on site wherein one or more wire frames are fastened to one another to form a structure substantially conforming to the dimensions of the original equipment manufacturer's filter housing. One or more of the wire frames are flexibly attached to each other end-to-end by flexible attachment means, allowing the assembled filter unit to be inserted into the filter housing one frame at a time, with the frame sections yet to be inserted folded or directed off to one side, thus bypassing space restrictions. Flexible attachment means may comprise spring connectors. Also disclosed is an end-cap affixed to or formed at one or both ends of the filter element. The end-caps may also contain printed material, such as text or pictures, which may include instructions for use, identifying labels or symbols, or the like.