Method for manufacturing a multilayer woven air filter consisting of activated carbon black particles based on the sequential lamination process (laminate)

A multilayer air filter with a lamination process and activated carbon black particles addresses carbon loss and air quality issues, enhancing pollutant removal and production efficiency in vehicle cabins.

IR114095BUndetermined Publication Date: 2026-06-20AKBAR KHODAMI
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Patent Information

Authority / Receiving Office
IR · IR
Patent Type
Patents
Current Assignee / Owner
AKBAR KHODAMI
Filing Date
2025-06-27
Publication Date
2026-06-20

AI Technical Summary

Technical Problem

Conventional air filters in car cabins face issues such as carbon loss, leakage, poor air quality, premature failure, and limited industrial production, leading to increased allergies and respiratory problems due to insufficient pollutant removal.

Method used

A multilayer air filter structure is produced using a sequential lamination process, comprising a pre-filter layer, a layer with activated carbon black particles and powdered adhesive, and a needle-punched nonwoven layer, with a continuous dry process to ensure stability and high absorption efficiency.

Benefits of technology

The multilayer filter achieves high pollutant absorption, reduced air pressure drop, extended lifespan, and cost-effective mass production with minimal environmental impact, while maintaining air quality in vehicle cabins.

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Abstract

A method for manufacturing a multilayer woven air filter consisting of activated carbon black particles based on a sequential lamination process (laminate) is proposed in this invention, which is used in the field of air conditioning, especially in car cabins. Conventional filter manufacturing methods have problems such as spillage of absorbent materials, carbon leakage, and high costs due to the complexity of the manufacturing process; in addition, many of these methods are non-continuous and wasteful. The claimed manufacturing method consists of sequentially laminating two layers of chemical and needle-punched nonwovens, between which a specific combination of thermosoft powder adhesive and activated carbon black is placed. During the sequential lamination process (laminating), the needle-punched nonwoven layer impregnated with activated carbon black is integrated with the chemical nonwoven layer in the heater chamber equipped with radiant heating elements, and interlayer adhesion occurs by means of the thermosoft powder adhesive melted at the junction of the layers. The use of a pair of pressure felt rollers to evenly distribute the molten adhesive is a later step in the process. Finally, the passage of the integrated multilayer through a set of guiding and cooling rollers results in the stability of the multilayer woven filter structure claimed in this invention.
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