An activated carbon filter and air purifier

Abstract

The application relates to the technical field of active carbon filter, in particular to an active carbon filter and an air purifier. The active carbon filter comprises a first filter layer and a second filter layer which are arranged in a stack. The first filter layer comprises a filter screen body and a plurality of honeycomb filter holes arranged on the filter screen body. In the air inlet direction of the honeycomb filter holes, the honeycomb filter holes comprise a guide section and a main section connected with the guide section, and the guide section is used for guiding the gas into the main section. The second filter layer comprises a base layer and active carbon particles. The base layer comprises a plurality of arrayed bearing through holes, and the active carbon particles are fixed at preset positions in the bearing through holes. The active carbon filter can effectively reduce the air resistance, improve the contact area between the air and the active carbon particles, thereby improving the air filtration efficiency and the energy efficiency of the air purifier.

Description

Technical Field

[0001] This application relates to the field of activated carbon filter technology, and in particular to an activated carbon filter and an air purifier. Background Technology

[0002] In existing air purifiers, activated carbon filters typically employ a honeycomb frame structure. However, this design has a critical drawback: its air intake side is flat. When air flows through this flat intake, it cannot smoothly enter the honeycomb channels, resulting in significant turbulence in front of the filter. This turbulence greatly increases airflow resistance.

[0003] Furthermore, the way the activated carbon particles are packed inside the filter also presents a problem. Currently, activated carbon particles are typically deposited by gravity into the individual cells of the honeycomb frame. These particles tend to accumulate at the bottom of each cell, resulting in uneven distribution throughout the filtration area. This accumulation and uneven distribution of activated carbon particles further exacerbates the resistance to airflow through the filter.

[0004] In summary, the design of existing activated carbon filters suffers from high overall air resistance due to unreasonable airflow organization at the air intake and uneven distribution of activated carbon particles inside. Higher air resistance requires the fan driving the airflow to consume more energy, thus reducing the overall energy efficiency of the air purifier. Utility Model Content

[0005] This application discloses an activated carbon filter and an air purifier to reduce the air resistance of the activated carbon filter and improve the energy efficiency of the air purifier.

[0006] To achieve the above objectives, this application provides the following technical solution:

[0007] In a first aspect, this application provides an activated carbon filter, comprising a first filter layer and a second filter layer stacked together. The first filter layer includes a filter body and a plurality of honeycomb filter holes disposed on the filter body. Along the air inlet direction of the honeycomb filter holes, each honeycomb filter hole includes a guide section and a main body section connected to the guide section, the guide section being used to guide gas into the main body section. The second filter layer includes a base layer and activated carbon particles. The base layer includes a plurality of arrayed support through-holes, and the activated carbon particles are fixed at predetermined positions within the support through-holes.

[0008] In the activated carbon filter of this application, the guiding section of the honeycomb filter pores can effectively guide the gas, allowing it to enter the main body section through the guiding section. This not only reduces the impact of the gas on the honeycomb filter pores but also enables the gas to enter the honeycomb filter pores smoothly. Furthermore, the base layer has multiple arrayed support through-holes, and the activated carbon particles are fixed in preset positions within these support through-holes. Therefore, the activated carbon particles are uniformly disposed on the base layer, increasing the contact area between the air and the activated carbon particles, thereby improving the filtration efficiency and optimizing the performance of the activated carbon filter.

[0009] In one possible implementation, the sidewall of the guide section is an arc-shaped sidewall, and the sidewall of the main body section is a straight sidewall. The tangent of the arc-shaped sidewall at the junction of the arc-shaped sidewall and the straight sidewall forms an angle α between the axis of the honeycomb filter and the opening of the angle α towards the air intake side of the honeycomb filter. The angle α is an acute angle.

[0010] In one possible implementation, the included angle α is 8-15°.

[0011] In one possible implementation, the activated carbon particles are fixed within the support through-hole by at least one of the following methods: bonding, snap-fitting, embedding, interference fit, and chemical bonding.

[0012] In one possible implementation, the base layer is provided with multiple vent holes, and the multiple vent holes and multiple load-bearing holes are arranged alternately.

[0013] In one possible implementation, the cross-sectional area of ​​the load-bearing through-hole is larger than the cross-sectional area of ​​the venting through-hole.

[0014] In one possible implementation, the substrate is a waveform plate with a wavelength of 11-13 mm and a wave height of 6-7.5 mm.

[0015] Understandably, compared to flat plates, corrugated plates have a significantly increased surface area, which increases the number of activated carbon particles and improves air filtration efficiency. Moreover, the corrugated plate's wave-shaped design can disperse the influence of airflow and reduce local high pressure conditions.

[0016] In one possible implementation, the activated carbon filter includes a frame layer, a second filter layer disposed between the first filter layer and the frame layer, the frame layer supporting the second filter layer, and the frame layer including a plurality of filter pores distributed in an array.

[0017] Secondly, this application provides an air purifier, which includes a front shell, a rear shell, and an activated carbon filter as described in the first aspect. The front shell and the rear shell are arranged to form a chamber, and the activated carbon filter is disposed in the chamber. The front shell is provided with an air inlet, and the rear shell is provided with an air outlet.

[0018] In the air purifier of this application, gas enters through the air inlet of the front shell, and after being filtered by the activated carbon filter, the gas is discharged through the air outlet of the rear shell. Because the activated carbon filter included in this application can effectively reduce air resistance and increase the contact area between the air and the activated carbon particles, thereby improving the air filtration efficiency and thus improving the energy efficiency of the air purifier in this application, making it more energy-saving and environmentally friendly.

[0019] In one possible implementation, the air purifier has an energy efficiency ratio greater than 13. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of an activated carbon filter according to an embodiment of this application;

[0021] Figure 2 This is a schematic diagram of the structure of the first filter layer according to an embodiment of this application;

[0022] Figure 3 This is a partial enlarged view of the first filter layer according to an embodiment of this application;

[0023] Figure 4 This is a schematic diagram of the structure of the second filter layer according to an embodiment of this application;

[0024] Figure 5 This is a cross-sectional view of a honeycomb filter pore according to an embodiment of this application;

[0025] Figure 6 This is a schematic diagram of the included angle between the arc-shaped sidewall and the straight sidewall of a honeycomb filter according to an embodiment of this application;

[0026] Figure 7 This is a cross-sectional view of the honeycomb filter pores according to another embodiment of this application;

[0027] Figure 8 This is a schematic diagram of the included angle between the arc-shaped sidewall and the straight sidewall of the honeycomb filter pores according to another embodiment of this application;

[0028] Figure 9 This is a schematic diagram of the structure of the second filter layer according to another embodiment of this application;

[0029] Figure 10 This is a schematic diagram of the structure of an activated carbon filter according to another embodiment of this application;

[0030] Figure 11 This is a schematic diagram of the structure of an air purifier according to an embodiment of this application;

[0031] Figure 12 This is an exploded view of an air purifier according to an embodiment of this application.

[0032] Reference numerals: 100 - First filter layer; 110 - Filter body; 121 - Arc-shaped sidewall; 122 - Straight sidewall; 200 - Second filter layer; 210 - Base layer; 220 - Activated carbon particles; 300 - Frame layer;

[0033] 10 - Activated carbon filter; 20 - Front shell; 30 - Rear shell;

[0034] 01-Honeycomb filter holes; 02-Bearing through holes; 03-Breathable through holes; 04-Filter through holes; 05-Air inlet; 06-Air outlet. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this application clearer, the application will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0036] The application scenarios described in this application are for the purpose of more clearly illustrating the technical solutions of this application, and do not constitute a limitation on the technical solutions provided in this application. Those skilled in the art will understand that with the emergence of new application scenarios, the technical solutions provided in this application are also applicable to similar technical problems. In the description of this application, unless otherwise stated, "multiple" means two or more.

[0037] Figure 1 This is a schematic diagram of the structure of an activated carbon filter according to an embodiment of this application. Figure 2 This is a schematic diagram of the structure of the first filter layer according to an embodiment of this application. Figure 3 This is a partial enlarged view of the first filter layer according to an embodiment of this application. Figure 4 This is a schematic diagram of the structure of the second filter layer according to one embodiment of this application. Please refer to it as well. Figures 1 to 4 This application provides an activated carbon filter 10, which includes a first filter layer 100 and a second filter layer 200 stacked together. The first filter layer 100 includes a filter body 110 and a plurality of honeycomb filter holes 01 disposed on the filter body 110. Along the air inlet direction of the honeycomb filter holes 01, each honeycomb filter hole 01 includes a guide section and a main body section connected to the guide section. The guide section guides the gas into the main body section. The guide section effectively guides the gas, allowing it to smoothly enter the main body section, effectively reducing the impact of the gas on the honeycomb filter holes 01 and thus reducing air resistance.

[0038] like Figure 4As shown, the second filter layer 200 includes a base layer 210 and activated carbon particles 220. The base layer 210 includes a plurality of support through holes 02 arranged in an array. The activated carbon particles 220 are fixed at preset positions within the support through holes 02. The preset positions can be designed according to the shape and structure of the support through holes 02 and other requirements, so that the activated carbon particles 220 can be evenly distributed on the base layer 210, preventing the activated carbon particles 220 from accumulating due to gravity. Furthermore, the arrayed support through holes 02 also contribute to the uniform distribution of the activated carbon particles 220, thereby reducing air resistance and improving the filtration efficiency of the activated carbon particles 220.

[0039] In some possible embodiments, Figure 5 This is a cross-sectional view of a honeycomb filter pore according to an embodiment of this application. Figure 6 This is a schematic diagram showing the included angle between the arc-shaped sidewall and the straight sidewall of a honeycomb filter according to an embodiment of this application. (Refer to...) Figure 5 and Figure 6 The sidewall of the guide section is an arc-shaped sidewall 121, and the sidewall of the main body section is a straight sidewall 122. The arc-shaped sidewall 121 forms an angle α between the tangent L at the connection between the arc-shaped sidewall 121 and the straight sidewall 122 and the axis M of the honeycomb filter 01. The opening of the angle α faces the air intake side of the honeycomb filter 01, and the angle α is an acute angle.

[0040] Understandably, the curved sidewall 121 has a streamlined effect, which can reduce the generation of fluid turbulence and eddies, reduce the possibility of fluid separation from the wall, thereby reducing flow resistance and making it easier for air to pass through. In addition, the curved inlet can help the fluid be distributed more evenly on the cross-section of the honeycomb filter 01, avoiding dead corners or areas with excessively high flow velocities.

[0041] In some embodiments of this application, the included angle α is 8-15°. Within this angle range, fluid resistance can be effectively reduced, and the generation of fluid turbulence and eddies can be minimized.

[0042] Among them, computational fluid dynamics (CFD) can be used to simulate and test the honeycomb filter 01 to analyze the air resistance of the honeycomb filter 01 under different structures and angles, so as to obtain the optimal shape and angle that are conducive to gas flow.

[0043] In other embodiments of this application, Figure 7 This is a cross-sectional view of the honeycomb filter pores according to another embodiment of this application. Figure 8 This is a schematic diagram showing the included angle between the arc-shaped sidewall and the straight sidewall of the honeycomb filter pores according to another embodiment of this application, with reference to... Figure 7 and Figure 8Along the air intake direction of the honeycomb filter 01, the cross-sectional area of ​​the main body of the honeycomb filter 01 gradually increases, thereby gradually reducing the airflow velocity. This helps to reduce turbulence and eddies in the airflow, allowing the airflow to enter the second filter layer 200 more smoothly. This reduces the impact of the airflow on the activated carbon particles 220 in the second filter layer 200. Moreover, the slower airflow velocity means that the pollutant molecules have a longer contact time with the activated carbon particles 220, which is conducive to the adsorption process and thus improves the air filtration efficiency of the activated carbon particles 220.

[0044] Continue to refer to Figure 8 Along the axial direction of the honeycomb filter pore 01, the length of the guide section is A, and the length of the main body section is B. Where A is less than B.

[0045] In this application, the shape of the honeycomb filter 01 is not limited. For example, the shape of the honeycomb filter 01 can be a quadrilateral, a hexagon, or other shapes, depending on the actual needs.

[0046] The structure and composition of the first filter layer have been described above. The shape, structure and material composition of the second filter layer will be explained below with reference to the accompanying drawings.

[0047] In some embodiments of this application, the activated carbon particles 220 are fixed in the bearing through hole 02 by means including but not limited to bonding, snapping, embedding, interference fit, chemical bonding, etc.

[0048] For example, activated carbon particles 220 can adhere to the support through hole 02. The above fixing method is simple and easy to operate.

[0049] For example, the diameter of the supporting through hole 02 is slightly smaller than the diameter of the activated carbon particles 220. The activated carbon particles 220 are pressed into the supporting through hole 02 to achieve tight embedding of the activated carbon particles 220 within the supporting through hole 02.

[0050] For example, Figure 9 This is a schematic diagram of the structure of the second filter layer according to another embodiment of this application, as shown below. Figure 9 As shown, the cross-sectional shape of the bearing through hole 02 can be dumbbell-shaped, that is, smaller in the middle and larger at both ends, and the activated carbon particles 220 are fixed in the middle position of the bearing through hole 02.

[0051] In some embodiments of this application, the base layer 210 is provided with a plurality of ventilating holes 03, and the plurality of ventilating holes 03 and a plurality of supporting holes 02 are arranged alternately to facilitate the diffusion of airflow in the supporting holes 02 to the adjacent ventilating holes 03 and to quickly flow out from the supporting holes 02. This facilitates airflow within the supporting holes 02 and reduces odors caused by gas accumulation and fermentation in the supporting holes 02.

[0052] In some embodiments of this application, the cross-sectional area of ​​the bearing through-hole 02 is larger than that of the air-permeable through-hole 03. With this configuration, the larger holes on the substrate layer 210 are used to fix the activated carbon particles 220, while the smaller holes are used for airflow, thereby improving the utilization rate of the substrate layer 210 and facilitating the fixation of more activated carbon particles 220.

[0053] In some embodiments of this application, the substrate layer 210 may be a corrugated plate. Compared to a flat plate, the surface area of ​​the corrugated plate is significantly increased, thereby increasing the number of activated carbon particles 220, improving the air filtration efficiency, and the corrugated plate's wave-shaped design can disperse the influence of airflow and reduce local high pressure conditions.

[0054] In some embodiments of this application, the wavelength of the waveform board is 11-13 mm. Exemplarily, the wavelength of the waveform board is 11 mm, 11.5 mm, 12 mm, 12.5 mm, 13 mm, or any other value between 11 and 13 mm.

[0055] In some embodiments of this application, the wave height of the waveform board is 6-7.5mm. Exemplarily, the wave height of the waveform board is 6mm, 6.5mm, 7mm, 7.5mm, or any other value between 6-7.5mm.

[0056] In some embodiments of this application, the substrate 210 is prepared from materials including metals, alloys, or organic polymers. This configuration results in a substrate 210 that is highly flexible, has high mechanical strength, is widely available, and is inexpensive.

[0057] When the substrate 210 is made of a metallic material, it can be made of stainless steel.

[0058] Figure 10 This is a schematic diagram of the structure of an activated carbon filter according to another embodiment of this application, with reference to... Figure 10 The activated carbon filter 10 may include at least two stacked second filter layers 200 to further enhance the air filtration effect of the activated carbon particles 220.

[0059] Continue to refer to Figure 10 The activated carbon filter 10 also includes a frame layer 300, and a second filter layer 200 is disposed between the first filter layer 100 and the frame layer 300. The frame layer 300 serves to support the second filter layer 200. The frame layer 300 includes a plurality of filter holes 04 arranged in an array, so that the airflow filtered by the second filter layer 200 flows out of the activated carbon filter 10 through the filter holes 04.

[0060] In this embodiment, the air resistance of the activated carbon filter 10 is less than 30 kPa, which is significantly lower than the air resistance of existing activated carbon filters (approximately 70 kPa).

[0061] Based on the same technical concept, this application provides an air purifier. Figure 11 This is a schematic diagram of the structure of an air purifier according to one embodiment of this application. Figure 12 This is an exploded view of an air purifier according to an embodiment of this application, with reference to... Figure 11 and Figure 12 The air purifier includes a front shell 20, a rear shell 30, and an activated carbon filter 10 in various possible embodiments of this application. The front shell 20 and the rear shell 30 are arranged to form a chamber, and the activated carbon filter 10 is disposed in the chamber. The front shell 20 is provided with an air inlet 05, and the rear shell 30 is provided with an air outlet 06.

[0062] Understandably, the gas enters through the air inlet 05 of the front shell 20, is filtered by the activated carbon filter 10, and is then discharged through the air outlet 06 of the rear shell 30. The activated carbon filter 10 in this embodiment can effectively reduce air resistance and improve the filtration efficiency of the activated carbon particles 220, thereby enhancing the performance of the air purifier.

[0063] In some embodiments of this application, the air inlet 05 may be elongated, and the air inlet 05 extends along the height direction of the front shell 20.

[0064] In some embodiments of this application, along the air intake direction of the air purifier, the air inlet 05 may include a guide portion and a main body portion connected in sequence. The function of the guide portion is to effectively guide the gas so that the gas smoothly enters the main body portion through the guide portion.

[0065] The guide section has an arc-shaped sidewall and the main body has a straight sidewall. The arc-shaped structure forms an angle β between the tangent at the junction of the arc-shaped structure and the straight sidewall and the axis of the air inlet 05. The opening of the angle β faces the air intake side of the air inlet 05, and the angle β is an acute angle.

[0066] In some embodiments of this application, the included angles α and β are the same or positively correlated, so that the gas passing through the air inlet 05 can smoothly enter the honeycomb filter 01.

[0067] The air purifier in this embodiment has an energy efficiency ratio (EER) greater than 13, meeting the Level 1 energy efficiency standard of the new national standard. In contrast, existing air purifiers only achieve an EER of 10.0, which meets the Level 3 energy efficiency standard of the new national standard.

[0068] Furthermore, compared to existing air purifiers, the clean air delivery rate (CADR) of the air purifier in this application embodiment can be increased by 10%, and the power consumption can be reduced by 10%. The air purifier in this application embodiment can significantly improve the removal rate of various gaseous pollutants.

[0069] It should be noted that the volume of the air purifier in this embodiment will not increase, and the noise level can be maintained at the same level as existing air purifiers.

[0070] The performance of the activated carbon filter 10 and the air purifier in the embodiments of this application will be described below with reference to specific examples and comparative examples.

[0071] Example 1

[0072] Example 1 provides an activated carbon filter 10 and an air purifier. The activated carbon filter 10 includes a first filter layer 100, a second filter layer 200, and a frame layer 300 stacked together. The first filter layer 100 includes a filter body 110 and a plurality of honeycomb filter holes 01 disposed on the filter body 110. Along the air intake direction of the honeycomb filter holes 01, each honeycomb filter hole 01 includes a guide section and a main body section connected to the guide section. The sidewall of the guide section is an arc-shaped sidewall 121, and the sidewall of the main body section is a straight sidewall 122. The tangent at the junction of the arc-shaped sidewall 121 and the straight sidewall 122 forms an angle α between the tangent and the axis of the honeycomb filter hole 01. The opening of the angle α faces the air intake side of the honeycomb filter hole 01, and the angle α is 8°. The second filter layer 200 includes a base layer 210 and activated carbon particles 220. Multiple air-permeable holes 03 and multiple support holes 02 are arranged alternately. The base layer 210 is a corrugated plate and includes multiple support holes 02 and air-permeable holes 03 arranged in an array. The activated carbon particles 220 are fixed in the middle position of the support holes 02.

[0073] The air purifier includes a front shell 20, a rear shell 30, and an activated carbon filter 10 with the above-described structure. The front shell 20 and the rear shell 30 are arranged to form a chamber, and the activated carbon filter 10 is disposed in the chamber. The front shell 20 is provided with an air inlet 05, and the rear shell 30 is provided with an air outlet 06.

[0074] Comparative Example 1

[0075] Comparative Example 1 provides an activated carbon filter and an air purifier. The activated carbon filter is a conventional activated carbon filter with a flat air intake side and no airflow guiding device. Activated carbon particles inside the filter are deposited by gravity in the individual cells of a honeycomb frame.

[0076] The air purifier includes a housing and an activated carbon filter with the aforementioned structure disposed within the housing.

[0077] The air purifiers in Example 1 and Comparative Example 1 were tested for air filtration under the same conditions, and the test results are shown in Table 1.

[0078] Table 1

[0079]

[0080] Referring to Table 1, compared with the air purifier in Comparative Example 1, the air purifier in Example 1 has a significantly improved adsorption effect on particulate matter and formaldehyde.

[0081] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An activated carbon filter, characterized in that, It includes a first filter layer and a second filter layer stacked together; wherein, The first filter layer includes a filter body and a plurality of honeycomb filter holes disposed on the filter body. Along the air intake direction of the honeycomb filter holes, the honeycomb filter holes include a guide section and a main body section connected to the guide section. The guide section is used to guide gas into the main body section. The second filter layer includes a base layer and activated carbon particles. The base layer includes a plurality of support pores distributed in an array, and the activated carbon particles are fixed at a predetermined position within the support pores.

2. The activated carbon filter according to claim 1, characterized in that, The sidewall of the guide section is an arc-shaped sidewall, and the sidewall of the main body section is a straight sidewall. The tangent of the arc-shaped sidewall at the connection between the arc-shaped sidewall and the straight sidewall forms an angle α between the axis of the honeycomb filter and the angle α. The opening of the angle α faces the air intake side of the honeycomb filter, and the angle α is an acute angle.

3. The activated carbon filter according to claim 2, characterized in that, The included angle α is 8-15°.

4. The activated carbon filter according to claim 1, characterized in that, The activated carbon particles are fixed in the bearing through-hole by at least one of the following methods: bonding, snap-fitting, embedding, interference fit, and chemical bonding.

5. The activated carbon filter according to claim 4, characterized in that, The base layer is provided with multiple air vents, and the multiple air vents and the multiple load-bearing vents are arranged alternately.

6. The activated carbon filter according to claim 5, characterized in that, The cross-sectional area of ​​the bearing through hole is larger than the cross-sectional area of ​​the venting through hole.

7. The activated carbon filter according to claim 1, characterized in that, The base layer is a waveform plate with a wavelength of 11-13 mm and a wave height of 6-7.5 mm.

8. The activated carbon filter according to any one of claims 1-6, characterized in that, The activated carbon filter includes a frame layer, and a second filter layer is disposed between the first filter layer and the frame layer. The frame layer is used to support the second filter layer, and the frame layer includes a plurality of filter holes distributed in an array.

9. An air purifier, characterized in that, The air purifier includes a front shell, a rear shell, and an activated carbon filter as described in any one of claims 1-8. The front shell and the rear shell are arranged to form a chamber, the activated carbon filter is disposed in the chamber, the front shell is provided with an air inlet, and the rear shell is provided with an air outlet.

10. The air purifier according to claim 9, characterized in that, The energy efficiency ratio of the air purifier is greater than 13.

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