Electronic air cleaner and method
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Solution Overview
Problem
Conventional electronic air cleaners (EACs) face challenges such as frequent cleaning and replacement needs, airflow resistance, and contamination of corona wires due to particle re-entrainment and ozone production, which increase energy consumption and maintenance costs in HVAC systems.
Innovation Solution
The use of an electronic air cleaner with a housing containing a plurality of first and second electrodes, both configured parallel to airflow, where the first electrodes have a high electrical resistivity and a porous, open-cell structure to collect particulate matter deep within the material, reducing surface accumulation and agglomeration, and repelling electrodes to direct charged particles effectively, minimizing pressure drop and extending cleaning intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional EACs use smooth metal collecting electrode plates parallel to airflow, then particle collection is achieved through electrostatic attraction, but particles accumulate on the outer surface and become re-entrained in the airflow, reducing filtration effectiveness
Solution Approach 1:
The patent applies porous materials by lining the collecting electrodes with open-cell foam material that allows particles to be collected within the porous structure rather than on the outer surface. The porous structure has interconnected cells that trap particles deep within the material, preventing re-entrainment while maintaining electrostatic collection efficiency.
Solution Approach 2:
The patent transitions from surface collection (2D) to volumetric collection (3D) by using open-cell foam material. Particles are collected throughout the volume of the porous structure rather than just on the surface, effectively utilizing the third dimension to increase collection capacity and prevent re-entrainment.
2Reliability
If fibrous media filters are placed perpendicular to airflow to mechanically remove particles, then particle collection is achieved, but airflow resistance and static pressure differential increase significantly
Solution Approach 1:
The patent replaces the mechanical filtration system (fibrous media perpendicular to airflow) with an electrostatic system. Collecting electrodes are positioned parallel to airflow direction, and charged particles are removed through electrostatic attraction to the electrodes rather than mechanical interception, significantly reducing airflow resistance.
Solution Approach 2:
The patent changes the orientation parameter of the collecting electrodes from perpendicular to parallel relative to the airflow direction. This parameter change, combined with electrostatic collection mechanism, allows particles to be removed without creating significant pressure drop across the filter.
3Reliability
If corona electrodes are used to ionize air and charge particles, then electrostatic particle collection is enabled, but corona wires become contaminated by oxidation and deposits, requiring frequent cleaning
Solution Approach 1:
The patent uses open-cell foam material with controlled porosity (20-80% open cell structure) that allows ion penetration while providing a large surface area for particle collection. The porous structure prevents particle buildup that would insulate the collecting electrodes, maintaining electrostatic efficiency over extended periods.
Solution Approach 2:
The patent creates a composite structure by combining the conducting foam material with an open-cell foam substrate. This composite provides both electrical conductivity for charge collection and porous structure for particle trapping, extending the operational life before cleaning is required.
4Reliability
If collecting electrodes accumulate particle layers to remove particles from airflow, then particle removal is achieved, but the accumulated particles increase airflow resistance and energy consumption
Solution Approach 1:
The patent employs open-cell foam material that provides extensive internal surface area within a compact volume. Particles are distributed throughout the porous structure rather than forming thick surface layers, maintaining low airflow resistance and energy consumption while achieving effective particle removal.
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 significantly reduces airflow resistance, extends cleaning intervals, and minimizes the need for frequent maintenance by effectively collecting and retaining particulate matter within the open-cell porous material, enhancing the air filtration efficiency and reducing energy consumption.
Implementation Method 1
creating an electric field using an ionizer arranged in an airflow path, such that the ionizer is positioned to ionize at least a portion of air molecules from the airflow
Implementation Method 2
applying a first electric potential at a plurality of first electrodes spaced apart from the ionizer, and receiving, at the first collection portion, particulate matter electrically coupled to the ionized air molecules
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Electronic air cleaners for use in heating, air-conditioning, and ventilation (HVAC) systems and associated methods and systems are disclosed herein. In one embodiment, an electronic air cleaner (100, 200, 300) includes one or more collecting electrodes (122, 322) having a collection material with a porous, open-cell structure and a conductive internal portion (125, 325). The collection material can be configured to collect and receive charged particulate matter in an airflow path. After a period of time, used collection material can be removed from individual collecting electrodes (122, 322) and replaced with new collection material.