Bellows Active Carbon Filter Layers for Low Pressure Loss
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Solution Overview
Problem
Existing filter elements with active carbon layers lack high adsorption capacity and efficient filtration efficiency, particularly in maintaining separation efficiency while minimizing pressure loss and ensuring flexibility for curved housing applications.
Innovation Solution
A filter element with a folded bellows configuration, comprising multiple layers of active carbon and cover layers, where additional filter layers are positively locked through fold alignment, allowing for minimal adhesive use and flexible non-woven connections to maintain efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple filter layers are stacked to increase adsorption capacity, then filtration efficiency improves, but device complexity increases
Solution Approach 1:
The filter element is divided into multiple identical filter layers, each consisting of a non-woven layer and an active carbon layer. These segmented layers are stacked and connected through fold alignment, allowing independent manufacturing of each layer while achieving high filtration efficiency through cumulative effect. The segmentation enables standardized production and simplifies assembly.
Solution Approach 2:
Multiple filter layers are nested within each other in a compact stacked arrangement. Each filter layer is folded into a bellows shape and nested within the housing space, maximizing the use of available volume. The nested structure allows multiple functional layers to occupy minimal space while maintaining their individual filtration and adsorption capabilities.
2Manufacturing precision
If filter layers are made rigid to improve structural stability, then manufacturing precision improves, but adaptability to curved housings deteriorates
Solution Approach 1:
The filter layers are designed with dynamic flexibility through the use of soft non-woven materials and a bellows-folded configuration. This allows the rigid-looking structure to actually bend and adapt to curved housing surfaces while maintaining its layered integrity. The dynamic nature of the folds enables the filter to conform to various housing geometries without compromising structural stability.
Solution Approach 2:
Soft non-woven material layers are used as flexible shells that can bend and conform to curved surfaces. These thin film-like non-woven layers provide the necessary flexibility for mounting in curved filter housings while maintaining filter integrity. The flexible non-woven material allows the filter element to adapt to different housing shapes without requiring rigid support structures.
3Reliability
If adhesive is used to secure active carbon particles, then reliability of particle position improves, but production cost increases
Solution Approach 1:
The active carbon particles are retained through the physical structure of the filter layer itself rather than requiring external adhesive binding. The non-woven layer structure and fold alignment mechanism naturally hold the particles in place during operation and reshaping, eliminating the need for additional adhesive materials and simplifying the manufacturing process.
4Adaptability or versatility
If filter layers are connected with lateral non-woven to enable curved housing mounting, then adaptability improves, but sealing reliability may deteriorate
Solution Approach 1:
The lateral non-woven connection serves multiple functions simultaneously: it provides flexible connection between filter layers enabling curved housing mounting, and also acts as a sealing element that closes off open sides of the filter layers. This multi-functional design eliminates the need for separate sealing components while maintaining both adaptability and sealing reliability.
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 enhances filtration efficiency, maintains minimal pressure loss, and allows for flexible mounting in curved housings, achieving high adsorption capacity and variability in separation degrees with minimal production expenditure.
Implementation Method 1
an adsorption of pollutants from the air to be cleaned by means of active carbon or other absorbent media is realized
Implementation Method 2
a beneficial particle filtration, for example, dust filtration
Data Source
AI summary
A filter element has a first filter layer that has an active carbon layer, a top cover layer connected to the active carbon layer and a bottom cover layer connected to the active carbon layer opposite the top cover layer, wherein the first filter layer is folded to a first bellows. At least one second filter layer having an active carbon layer, a top cover layer connected to the active carbon layer and a bottom cover layer connected to the active carbon layer opposite the top cover layer is provided. The at least one second filter layer is folded to a second bellows. The first and second bellows are folded identically. The at least one second filter layer is arranged on the first filter layer in a positive-locking way by fold alignment of the first and second bellows to form a composite of filter layers.