Filter media design using spacers and media in predetermined arrangements
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Solution Overview
Problem
Current gas phase contaminant removal systems in buildings face challenges such as high pressure drop, inefficient media utilization, and turbulence due to the limitations of traditional sorbent media designs, particularly in HVAC systems, which affect the effectiveness and operational costs of air cleaning.
Innovation Solution
A modular filter media design with controllable variable media length and path length, oriented at an optimal angle to airflow, which ensures a contained Mass Transfer Zone (MTZ) length and low pressure drop, utilizing channels and spacers to maximize exposure to filter media and minimize turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sorbent media designs are used, then gas phase contaminant removal is achieved, but high pressure drop and turbulence occur
Solution Approach 1:
The filter media is divided into multiple layers with different orientations (0 degrees, 45 degrees, 90 degrees) relative to the airflow. Each layer segment serves a specific function in controlling the Mass Transfer Zone and reducing pressure drop, while collectively achieving effective contaminant removal.
Solution Approach 2:
The patent introduces angular orientation as a new dimension for media arrangement. By orienting media layers at different angles (0°, 45°, 90°) relative to the airflow direction, the system optimizes both contaminant capture efficiency and pressure drop characteristics, adding a dimensional parameter that was not present in traditional designs.
2Reliability
If traditional sorbent media designs are used, then contaminant removal is achieved, but inefficient media utilization occurs
Solution Approach 1:
The media is segmented into layers with different orientations to optimize the Mass Transfer Zone containment. This segmentation ensures that each layer contributes effectively to contaminant removal, maximizing the utilization of the entire media depth and preventing wasted media capacity.
Solution Approach 2:
Different media layers are assigned different orientations (0°, 45°, 90°) based on their local function within the filter. The 0° layer handles initial contaminant capture, while subsequent layers at different angles optimize the MTZ progression, ensuring each local region of the media operates at maximum efficiency.
3Duration of action of moving object
If media path length is increased to improve contaminant capture, then dwell time increases, but pressure drop increases
Solution Approach 1:
By introducing angular orientation as a control dimension, the patent achieves longer effective path length and increased dwell time without proportionally increasing pressure drop. The angled layers (45°, 90°) extend the contaminant exposure path while maintaining airflow efficiency.
Solution Approach 2:
The path length is segmented across multiple oriented layers rather than using a single long path. This segmentation allows the airflow to progress through each layer efficiently, accumulating dwell time benefits while managing pressure drop across the staged structure.
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 design enhances the efficiency and operational life of gas phase contaminant removal systems by optimizing dwell time and pressure drop, allowing for more effective capture of contaminants while reducing energy costs and maintaining air quality.
Implementation Method 1
Gas phase contaminant and/or compound removal systems can be large, expensive, difficult to install and costly to maintain. Gas phase contaminant removal has generally been achieved by putting air in contact with adsorbents, absorbents, chemi-sorbents, photocatalysts, catalysts, molecular sieves, or other material with removal properties, referred to herein as sorbents.
Implementation Method 2
The MTZ is the section in a sorbent where active adsorption occurs and the MTZ length depends on the sorbent (type, amount, structure, etc.) and the conditions (face velocity, contaminant, concentration, etc.)
Data Source
AI summary
A media design for modular use in an air cleaning or HVAC systems to removes gas phase contaminants. The design allows for a control of gas contaminant removal using variable media length, path length, and contact time to ensure a contained MTZ length and low pressure drop. In one embodiment, the design includes a filter module at an angle to an airflow and an air filter mounted within the filter frame. The filter module may include channels therethrough that are oriented at the optimum angle in relation to the airflow to provide the required dwell time and pressure drop for a given application.