Activated Carbon Filter Element for Compact Harmful Substance Adsorption
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Solution Overview
Problem
Existing filter elements for fluids, particularly those using activated carbon, are limited in configuration and efficiency, especially in adsorbing harmful substances, and lack a method for producing them in beneficial forms.
Innovation Solution
A filter element and system are designed with a flow-through medium filled with adsorption medium, such as particle-type or dust-type activated carbon, covered by a fluid-permeable cover medium, allowing for compact and efficient filtration and adsorption of harmful substances, with production methods involving filling intermediate spaces and covering with spunbond nonwoven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If activated carbon is used as granular material, honeycomb body, or pellet, then the filter structure is simple and easy to manufacture, but the adsorption capacity is limited due to smaller surface area
Solution Approach 1:
The invention changes the physical form parameter of activated carbon from granular/pellet to dust-type with significantly enlarged surface area, thereby increasing adsorption capacity while maintaining manufacturability through the corrugated web structure
Solution Approach 2:
The invention uses dust-type activated carbon which creates a porous structure with greatly increased surface area within the corrugations of the filter web, enhancing adsorption capacity for hydrocarbons and other harmful substances
2Quantity of substance
If dust-type activated carbon is used to increase adsorption capacity, then the adsorption capacity is significantly increased, but the filter element becomes more complex and difficult to produce
Solution Approach 1:
The invention divides the filter element into multiple corrugated filter webs with corrugations of different amplitudes and wavelengths, creating segmented layers that collectively hold the dust-type activated carbon while maintaining structural integrity
Solution Approach 2:
The invention creates a composite structure combining multiple filter media layers (flat and corrugated webs) with dust-type activated carbon filled in the corrugations, achieving both high adsorption capacity and structural stability
3Quantity of substance
If multiple corrugated filter webs with different corrugations are used, then the adsorption capacity is increased, but the manufacturing complexity and production difficulty increase
Solution Approach 1:
The invention segments the activated carbon storage function across multiple corrugated layers with different corrugation parameters, allowing each layer to contribute to adsorption capacity while the modular structure facilitates production
Solution Approach 2:
The corrugated filter webs serve multiple functions: structural support, flow distribution, and activated carbon containment, reducing the need for additional components and simplifying overall manufacturing
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 solution enables both dust removal and harmful substance adsorption in a compact space, supporting various configurations, including cubic and slanted shapes, suitable for motor vehicles and air purifiers, enhancing adsorption capacity and versatility.
Implementation Method 1
activated carbon which adsorbs and thus fixes the hydrocarbons
Implementation Method 2
the region is covered with a fluid-permeable cover medium, for example a spunbond nonwoven
Data Source
AI summary
A filter element for fluid has a filter medium body with a flow-through medium arranged transversely to a fluid flow direction. A region of the flow-through medium between an inlet surface and an outlet surface of the filter medium body is filled with adsorption medium in intermediate spaces of the flow-through medium. A fluid-permeable cover medium covers the region at a peripheral rim of the inlet surface and/or the outlet surface. A filter system has a filter housing having an inlet and an outlet for fluid. The filter element is exchangeably arranged in the filter housing between a raw-side and a clean-side. A method for producing the filter element includes filling adsorption medium into intermediate spaces of the flow-through medium between an inlet surface and an outlet surface. The region is covered with a fluid-permeable cover medium at a peripheral rim of the inlet surface and/or the outlet surface.