Curved Ceramic Ducts for Compact Air Sterilization
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Solution Overview
Problem
Existing air sterilization systems are limited by the use of straight ducts, which restrict size reduction and flexibility, leading to larger external dimensions and reduced design options for air sterilization devices.
Innovation Solution
The introduction of curved or non-straight ducts within a ceramic block assembly, allowing for reduced external size while maintaining or increasing air residence time, achieved by stacking plates with pre-formed half-ducts that can be configured in various shapes and sizes, and optionally incorporating activated carbon and fans for enhanced air flow and filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight ducts are used in air sterilization systems, then the system structure is simple and easy to manufacture, but the external dimensions are large and design flexibility is limited
Solution Approach 1:
The patent applies curvature principle by transforming straight ducts into curved or bent ducts within the ceramic block. This allows the ducts to fold back on themselves multiple times, increasing the effective duct length and air residence time within a compact external volume, thereby reducing the overall device size while maintaining sterilization effectiveness
Solution Approach 2:
The patent implements nesting by having ducts fold back and coil within the ceramic block structure. The ducts are arranged to nest within the available space, with each duct making multiple bends and turns to maximize the path length through the sterilization zone without increasing the external footprint of the device
2Ease of manufacture
If straight ducts are used in air sterilization systems, then the manufacturing process is straightforward, but design flexibility and configuration options are reduced
Solution Approach 1:
The curvature principle enables diverse duct configurations by allowing ducts to be bent at various angles and directions. This provides design flexibility to create different flow patterns and adapt to various installation spaces while still using the same extrusion manufacturing process for the ceramic block
Solution Approach 2:
The patent applies dynamics by making the duct configuration adaptable rather than fixed. The curved duct design allows for different bend radii, angles, and patterns to be incorporated into the ceramic block, enabling the system to adapt to different air flow requirements and spatial constraints while maintaining a straightforward extrusion manufacturing process
3Volume of moving object
If curved ducts are used to reduce external size, then the external dimensions are reduced, but the duct length and air residence time must be maintained
Solution Approach 1:
The curved duct configuration allows the duct to achieve a longer effective length by folding back on itself within the compact ceramic block. The curvature enables the duct to utilize three-dimensional space efficiently, creating multiple bends and turns that extend the air residence path without increasing the external dimensions of the device
Solution Approach 2:
The patent applies dimensionality change by transitioning from straight linear ducts to curved three-dimensional duct paths within the ceramic block. This allows the duct to exploit the vertical and lateral dimensions of the block to create extended flow paths, maintaining adequate air residence time while reducing the device's external footprint
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 compact, flexible air sterilization systems that effectively reduce airborne microorganisms, organic smells, and fungi, while allowing for various device sizes and configurations, including smaller and larger designs, with efficient heat distribution and low heat contribution to the surrounding environment.
Implementation Method 1
Heating elements in the form of NiCr resistive wire filaments having a resistance of 100 ohm/meter are placed in the small diameter ducts, connected in series (4.5 meters), and energized with rectified current from a 110 volt home outlet to dissipate 24.4 Watts. Room air will circulate upwardly through the ducts by convection and will become sterilized by energy dissipated by the Joule heating effect wherein a high thermal gradient is produced in the interior of the ducts (220° C.) during the traverse through the ducts.
Implementation Method 2
Room air will circulate upwardly through the ducts by convection and will become sterilized by energy dissipated by the Joule heating effect wherein a high thermal gradient is produced in the interior of the ducts (220° C.) during the traverse through the ducts.
Data Source
AI summary
The formation of sterilization tubes by plates with parts that match in whole or in part, that when assembled together form ducts, passages, channels, or tubes in a mass or block of heat resistant material. The size of the block may be reduced by forming the ducts as curved passages or tubes that will keep or increase the length of the tube while keeping the same or more exposure time while the gas is passing through. If the length of the curved duct is the same as a straight tube would have been, the overall size of the assembly may be reduced from what it otherwise would have been. If the curved length is made longer while the size of the assembly is kept the same, the exposure time is increased for a more effective sterilization.