Stacked Air Filter With Charged Intermediate Layer

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Solution Overview

Problem

Existing air cleaner filter materials struggle to effectively adsorb chemical substances like formaldehyde while maintaining dust collection performance, often requiring complex configurations and increased costs due to issues with adsorbent dispersion and adhesion.

Innovation Solution

A stacked body comprising a porous base layer, a charged layer, and a very fine-fiber layer with adsorbent held within the very fine fibers, where the charged layer captures larger dust and protects the fine fibers, and the fine fibers capture finer dust and chemical substances, preventing adsorbent fallout through electrostatic forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the adsorbent is mixed with hot melt adhesive and sprinkled on the base layer, then the adsorbent is fixed to the base layer, but the surface of the adsorbent is covered with adhesive and its adsorption function is not sufficiently exhibited

Engineering Contradiction:

Improveadsorbent fixationVSAvoidadsorption function

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The filter is divided into multiple functional layers: base layer, intermediate layer (with adsorbent), and surface layer. The adsorbent is embedded in the intermediate layer rather than being sprinkled on the base layer, separating the fixation function (base layer) from the adsorption function (intermediate layer), allowing both to be optimized independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A charged fiber intermediate layer is introduced between the base layer and surface layer to hold the adsorbent particles. This intermediate layer acts as a mediator that provides both mechanical support for the adsorbent and electrostatic attraction to prevent adsorbent fallout, without covering the adsorbent surface with adhesive.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If adhesive is not used to fix the adsorbent, then the adsorbent surface is not covered and adsorption function is exhibited, but the adsorbent falls down

Engineering Contradiction:

Improveadsorption functionVSAvoidadsorbent stability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The mechanical adhesion system (hot melt adhesive) is replaced with an electrostatic field system. The charged fibers in the intermediate layer generate electrostatic forces that attract and hold the adsorbent particles, eliminating the need for adhesive while preventing adsorbent fallout through non-contact forces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The physical state of the intermediate layer is changed from neutral to charged by incorporating charged fibers. This parameter change (electrical charge) enables the intermediate layer to exert electrostatic forces on the adsorbent particles, providing fixation without mechanical adhesion.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If a simple structure is used, then manufacturing is easier and cost is lower, but dust collection performance and adsorption function cannot be simultaneously achieved

Engineering Contradiction:

Improvestructural simplicityVSAvoiddust collection and adsorption performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The charged fiber intermediate layer serves multiple functions simultaneously: it provides mechanical support for the adsorbent, generates electrostatic forces to prevent adsorbent fallout, and contributes to dust collection through its charged fibers. This multi-functionality reduces the need for separate components while maintaining both dust collection and adsorption performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration enables efficient dust collection and chemical substance adsorption with a simple structure, suppressing adsorbent fallout and maintaining performance over time, thus serving as an effective filter material for air cleaners and other applications.

Implementation Method 1

a porous charged layer... The charged layer is configured with charged fiber

Methodology Applied

Scientific EffectElectrostatic force: Electrostatics

Implementation Method 2

The adsorbent is held in the very fine fiber and adsorbs a chemical substance

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS10413856B2Stacked body

Publication Date: 2019.09.17 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

There is provided a stacked body which includes a porous base layer, a porous charged layer, a very fine-fiber layer, and an adsorbent. The base layer is configured with base fiber. The charged layer is configured with charged fiber. The very fine-fiber layer is interposed between the base layer and the charged layer and includes very fine fiber. The adsorbent is held in the very fine fiber and adsorbs a chemical substance. An average fiber diameter of the charged fiber is greater than an average fiber diameter of the very fine fiber.