Fan Filter Unit Aerosol Injector Ring for Uniform Cleanroom Testing
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Solution Overview
Problem
Current roomside replaceable filter units in cleanrooms require large quantities of aerosol for testing, leading to inefficiency and unnecessary loading of filters, which reduces availability and increases waste, as aerosol distribution is not uniform and requires time to stabilize.
Innovation Solution
Integration of an aerosol injector ring within the fan filter unit allows for direct aerosol challenge upstream of the fan module, reducing the amount of aerosol needed and ensuring uniform distribution, enabling individual filter testing without affecting adjacent filters, thus optimizing resource use and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If aerosol challenge is provided to a common plenum feeding multiple filters, then uniform aerosol concentration can be achieved for testing, but large quantities of aerosol are wasted and adjacent filters are unnecessarily loaded
Solution Approach 1:
The patent introduces separate aerosol injection ports for each individual filter unit within the common plenum system. This segmentation allows aerosol to be injected directly at each filter location rather than distributing aerosol throughout the entire plenum, thereby achieving uniform concentration at each test point while minimizing overall aerosol consumption and preventing unnecessary loading of adjacent filters.
2Measurement precision
If large quantities of aerosol are provided to charge the plenum, then sufficient uniform concentration is achieved for testing, but the time required to stabilize aerosol concentration increases
Solution Approach 1:
The patent implements preliminary aerosol injection directly at each filter unit's injection port before the actual filtration efficiency test begins. This preliminary action pre-charges the immediate testing zone with aerosol, eliminating the need to wait for the entire plenum to reach stable concentration, thereby significantly reducing the time required to achieve test-ready conditions.
3Reliability
If aerosol is distributed throughout the common plenum, then all filters receive aerosol challenge, but adjacent filters are unnecessarily loaded reducing system availability
Solution Approach 1:
The patent provides aerosol challenge locally at each individual filter unit through dedicated injection ports positioned adjacent to each filter. This local quality approach ensures that aerosol is applied only where needed for testing, preventing unnecessary loading of adjacent filters that are not undergoing testing, thereby maintaining higher system availability and productivity.
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 solution significantly reduces aerosol usage, enhances testing efficiency, and maintains filter performance by ensuring uniform aerosol distribution, allowing for accurate and timely certification of filters without disrupting normal cleanroom operations.
Implementation Method 1
an aerosol challenge is provided at a location adjacent and upstream of the fan module
Implementation Method 2
Air is then pulled into a housing of the replaceable fan filter unit and out through the replacement filter to the roomside by a fan module
Data Source
AI summary
Embodiments described herein relate to a method for utilizing a roomside replaceable fan filter unit having an integral aerosol injector ring. The method begins by replacing a used filter from the fan filter unit with a replacement filter from a roomside of the fan filter unit. Air is then pulled into a housing of the replaceable fan filter unit and out through the replacement filter to the roomside by a fan module. Finally, an aerosol challenge is provided at a location adjacent and upstream of the fan module.