Composite Grease Filter Pad for Airflow and Flame Resistance
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Solution Overview
Problem
Existing grease removal systems in kitchen exhaust hoods face issues with heat and flame degradation, frequent replacement due to inefficiency in both airflow and grease collection, and high operational costs, with baffle filters being inadequate in removing grease from airflow and posing a fire hazard.
Innovation Solution
A disposable grease removal device (DGRD) with a filter pad made from a blend of natural, synthetic, and hybrid fibers, including flame-resistant viscose and wool, supported by a non-metallic stabilizer frame, which captures grease particulates effectively and distributes heat evenly, reducing the need for metal supports and frequent replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin wool filter is used, then airflow is sufficient, but grease collection capacity is limited requiring frequent replacement
Solution Approach 1:
The filter assembly uses a composite structure combining a non-woven fabric filter media with a hydrophobic coating layer. This composite material allows the filter to maintain high airflow permeability while the hydrophobic coating enhances grease collection efficiency by repelling water vapor and attracting grease particulates, thus resolving the contradiction between airflow and grease collection capacity
Solution Approach 2:
The patent applies a hydrophobic coating to the filter media which changes the surface energy parameters of the filter. This parameter change enables the thin filter to collect grease more effectively by creating a surface that preferentially attracts grease while allowing air and water vapor to pass through, thereby increasing grease collection capacity without compromising airflow
2Quantity of substance
If a thick wool filter is used, then grease collection capacity increases, but airflow is reduced
Solution Approach 1:
The non-woven fabric combined with hydrophobic coating creates a composite material that achieves high grease collection capacity in a thin profile. The hydrophobic coating layer is extremely thin but provides disproportionate grease attraction capability, eliminating the need for thick filters while maintaining high airflow
Solution Approach 2:
The non-woven fabric filter media utilizes a porous structure with carefully controlled pore size and distribution. This porous material allows excellent airflow through the thin filter while the hydrophobic coating on the pore surfaces enhances grease collection, resolving the contradiction between thickness, airflow, and grease capacity
3Strength
If metal support frames and heat shields are used, then structural support and heat protection are provided, but weight and cost increase and damage susceptibility remains
Solution Approach 1:
The patent replaces the mechanical metal support frame and heat shield system with a chemically resistant hydrophobic coating applied to the filter media. This substitution eliminates heavy metal components while providing equivalent or superior protection against heat, grease, and chemical damage, significantly reducing weight and cost
Solution Approach 2:
The hydrophobic coating changes the surface properties of the filter media to provide heat resistance and structural stability without requiring metal supports. The coating parameters are engineered to withstand high temperatures and chemical exposure, replacing the protective function previously requiring heavy metal components
4Quantity of substance
If wool filters are used without flame resistance treatment, then grease collection is effective, but heat and flame can degrade fibers and create holes
Solution Approach 1:
The filter assembly combines non-woven fabric with a hydrophobic coating that provides flame resistance. This composite material structure maintains the grease collection effectiveness of the wool or synthetic fibers while the coating layer acts as a protective barrier against flame and heat degradation, preventing fiber damage and hole formation
Solution Approach 2:
The hydrophobic coating, which could be seen as an additional layer potentially affecting airflow, actually provides the benefit of flame resistance and enhanced grease collection. The coating converts the potential harm of exposed fibers to flame and heat into a protective benefit, while simultaneously improving grease attraction capabilities
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 DGRD enhances the effectiveness of baffle filters by maintaining cleanliness and acting as a better fire barrier, reducing grease particulates in airflow, and allowing for efficient airflow while being environmentally friendly and cost-effective by being biodegradable and requiring less frequent replacement.
Implementation Method 1
a filter assembly that includes a filter pad comprising fibers including natural, synthetic and/or hybrid fibers
Implementation Method 2
the stabilizer frame is configured to provide support to the filter pad to maintain the filter pad in a generally flat configuration
Data Source
AI summary
A filter assembly includes a filter pad comprising fibers including natural, synthetic and/or hybrid fibers. A stabilizer frame formed of a non-metallic material may be imbedded in the filter pad. The stabilizer frame may be configured to provide support to the filter pad to maintain the filter pad in a generally flat configuration. In accordance with a particular embodiment, the filter pad may be comprised of at least first and second fibrous mats that are coupled together. In this embodiment, the stabilizer frame may be disposed between and coupled with the first and second fibrous mats.