Air Purifier Filter With 3D Corrugated Substrate
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Solution Overview
Problem
Existing air purifier filters face issues with uneven filling of filtering agents, leading to inconsistent airflow and filtration amounts, which decreases product reliability and filtration efficiency, and previous solutions like stacked nets or excessive pellet attachment do not efficiently address the problem of even distribution and pressure loss.
Innovation Solution
An air purifier filter with a substrate having a three-dimensional corrugated structure and a mesh cover, where the filtering agent is attached to the substrate, ensuring even distribution and preventing leaning when tilted, thereby maintaining constant airflow and filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If activated carbon is filled in multiple compartments of the filter body, then the filter structure is formed, but the activated carbon is unevenly filled in each compartment leading to inconsistent airflow and filtration amount
Solution Approach 1:
The filter body is divided into multiple compartments, each independently filled with activated carbon. This segmentation allows for standardized filling processes in each compartment while maintaining overall filter functionality.
Solution Approach 2:
The invention changes the physical state of activated carbon from loose granular form to pressed compact form. By applying pressure to compact the activated carbon in each compartment, the filling becomes uniform and consistent, eliminating the uneven distribution problem while maintaining reliable airflow through all compartments.
2Quantity of substance
If activated carbon is excessively filled in the compartments, then the filtration amount increases, but the covers cannot adhere to the filter body and activated carbon may be removed
Solution Approach 1:
The activated carbon is transformed from a loose state to a compacted state through pressing. This parameter change in density and volume allows maximum filtration capacity within the compartment space while preventing excessive filling that would prevent cover adhesion. The compacted form maintains structural integrity and prevents carbon removal.
3Reliability
If the filter body is tilted, then the activated carbon focuses in the gravitational direction, but the gaps become non-uniform and airflow is not constant reducing filtration efficiency
Solution Approach 1:
The activated carbon is compacted under pressure to create a dense, interlocked structure within each compartment. This compaction eliminates the uniform gap structure that would allow gravitational settling and carbon focusing when tilted. The pressed configuration maintains stable airflow paths regardless of filter orientation, preventing the non-uniform gap formation that occurs with loose carbon.
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 ensures consistent airflow and filtration efficiency by evenly distributing the filtering agent, improving product reliability and reducing pressure loss, while also simplifying the manufacturing process with integral formation of the substrate and filtering agent.
Implementation Method 1
configured to have a filtering agent, such as activated carbon and zeolite having excellent adsorption power for foreign matter, filled in a filter core
Data Source
AI summary
An air purifier filter is proposed. The air purifier filter includes: a filter body having an inlet and an outlet therein such that air flows therethrough, and a receiving space having formed therein; a substrate provided in the receiving space of the filter body; and activated carbon attached to a surface of the substrate, wherein the substrate has a three-dimensional corrugated structure.