A dryer having improved filter
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Solution Overview
Problem
Existing dryer filters, whether woven or non-woven, face issues with frequent cleaning needs, energy inefficiency, and short lifespan due to clogged pores and fiber leakage, leading to decreased user satisfaction and increased service costs.
Innovation Solution
A 3D fabric filter structure with a breathable upper and lower layer and a spacer layer, arranged perpendicularly to the air flow, providing high filtering performance and strength while minimizing air flow losses, and featuring monofilament or multifilament yarns and chemical treatments for easy cleaning and extended maintenance intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If woven fabric filters are used for filtering, then filtering performance is achieved, but the filter pores become clogged at the end of each cycle requiring frequent cleaning
Solution Approach 1:
The patent transitions from traditional 2D flat filter fabric to a 3D spatial filter structure with depth and volume. The filter medium is arranged in a three-dimensional configuration within the air duct, creating multiple filtering surfaces and pathways that prevent pore clogging by distributing captured particles throughout the 3D space rather than confining them to a single plane.
Solution Approach 2:
The patent employs porous filter materials with optimized pore structures that maintain open channels for air flow while capturing particles. The porous structure allows particles to be trapped within the interconnected void spaces without blocking the overall airflow paths, preventing the clogging issue that occurs in traditional dense 2D filters.
2Ease of operation
If non-woven fabric filters are used, then cleaning frequency is reduced, but the fabric strength is low causing disintegration and tearing
Solution Approach 1:
The patent uses composite filter structures combining different materials with complementary properties. The filter assembly integrates a porous support structure providing mechanical strength with a filtering medium that captures particles. This composite approach allows the filter to withstand the mechanical stresses of the dryer environment while maintaining effective particle capture and reducing cleaning frequency.
Solution Approach 2:
The patent applies different material properties to different regions of the filter structure. The support framework uses high-strength materials to provide structural integrity, while the filtering surfaces use materials optimized for particle capture. This local differentiation of material properties ensures both strength and low maintenance without requiring the entire filter to be made of high-strength material.
3Ease of operation
If non-woven fabric filters are used, then cleaning frequency is reduced, but filtering of small particles is poor and leakage occurs
Solution Approach 1:
The patent employs a 3D filter configuration that provides multiple filtering surfaces and extended airflow paths. This three-dimensional arrangement increases the total filtering surface area and creates longer residence times for particles to be captured, improving small particle filtration effectiveness without requiring frequent cleaning.
Solution Approach 2:
The patent utilizes porous filter materials with optimized pore size distributions that effectively capture small particles while maintaining adequate airflow. The porous structure provides numerous capture sites throughout the 3D volume, ensuring thorough filtration of fine particles without clogging or requiring frequent maintenance.
4Ease of manufacture
If traditional 2D fabric filters are used, then manufacturing simplicity is maintained, but air flow losses increase causing energy consumption to rise
Solution Approach 1:
The patent transitions from 2D flat filters to 3D spatial filter structures that optimize airflow patterns. The three-dimensional configuration creates more efficient airflow paths with reduced turbulence and pressure drops, minimizing energy losses while maintaining effective particle capture. The 3D structure allows air to flow through multiple pathways simultaneously, reducing resistance compared to single-plane 2D filters.
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 3D fabric filter ensures efficient air filtration with reduced energy consumption, extended filter cleaning intervals, and a longer economic life, enhancing user satisfaction and meeting quality criteria by maintaining high filtering performance and strength.
Implementation Method 1
a spacer layer in the form of spacer yarns which is disposed between the lower layer and the upper layer and which ensures air passage
Implementation Method 2
passes over the laundry or textile and leaves the fluff and fibers therein by means of a filter
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a dryer (1) comprising a body (2), an air duct (3) which is disposed in the body (2) and which provides the air circulation during the air cycle, and a filter (7) with a 3D fabric structure composed of various layers.