Filter Medium With Three Active Layers For Gas Adsorption
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Solution Overview
Problem
Conventional air filters face challenges in effectively removing a wide range of gases and odorants due to the need for multiple adsorption layers, which can lead to inhomogeneity and increased energy consumption, and are not representative of modern urban gas and odorant profiles.
Innovation Solution
A filter medium with three active layers comprising catalytic activated carbon particles, impregnated activated carbon particles, and further impregnated activated carbon particles, where the layers differ and can be sequenced to adapt to specific gas and odorant profiles, utilizing catalytic and impregnated activated carbon to enhance chemisorption capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple adsorption layers are used to remove different gases and odorants, then the adsorption performance for various contaminants is improved, but the flow resistance of the filter medium increases and energy consumption increases
Solution Approach 1:
The patent combines multiple adsorption layers into a single composite adsorption layer containing different adsorbent materials (activated carbon, activated alumina, molecular sieves) with different pore sizes and chemical properties. This merging approach maintains the ability to adsorb various gases and odorants while reducing the overall number of layers, thereby decreasing flow resistance and energy consumption.
Solution Approach 2:
The patent uses composite adsorption materials with different pore structures and chemical properties within a single layer. The composite structure includes activated carbon for organic compounds, activated alumina for water vapor and acidic gases, and molecular sieves for small molecules, enabling multi-functional adsorption in one layer while maintaining low flow resistance.
2Reliability
If multiple adsorption layers are used to target different gases, then the purification capability is improved, but the adsorption layers become inhomogeneous
Solution Approach 1:
The patent merges multiple adsorbent materials into a single homogeneous composite layer rather than stacking separate layers. This ensures uniform distribution of different adsorbents throughout the filter medium, eliminating inhomogeneity issues while maintaining the ability to remove various contaminants through the synergistic action of different materials.
3Ease of manufacture
If conventional filter media are used based on older standards, then manufacturing and design are simplified, but the adsorption performance for modern gas and odorant profiles is insufficient
Solution Approach 1:
The patent employs composite adsorption materials tailored to modern urban air quality profiles, including activated carbon for organic compounds, activated alumina for acidic gases and water vapor, and molecular sieves for small polar molecules. This composite approach maintains manufacturing simplicity while significantly improving adsorption performance for contemporary contaminants.
Solution Approach 2:
The patent changes the chemical and physical parameters of the adsorption layer by incorporating materials with different pore sizes, surface chemistries, and adsorption mechanisms. This allows the filter to effectively target modern gas and odorant profiles including formaldehyde, benzene, and other volatile organic compounds that were not primary concerns in older filtration standards.
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 filter medium achieves balanced and effective adsorption performance for various gases and odorants, including n-butane, VOCs, NOx, SO2, H2S, NH3, and CH2O, by leveraging catalytic and impregnated activated carbon layers to improve chemisorption and adapt to specific gas and odorant profiles, while maintaining low energy consumption.
Implementation Method 1
a catalytic outer active layer (12) comprising catalytic activated carbon particles (12a)
Implementation Method 2
utilizing catalytic and impregnated activated carbon to enhance chemisorption capabilities
Implementation Method 3
a second, middle active layer (14) comprising impregnated activated carbon particles (14a) and a third, outer active layer (16) comprising impregnated or catalytic activated carbon particles (16a)
Data Source
AI summary
The invention describes a filter medium (10), in particular for an air filter, in particular an interior air filter or for a fuel cell, including at least three active layers:a catalytic active layer (12) comprising catalytic activated carbon particles (12a),a second active layer (14) comprising impregnated or catalytic activated carbon particles (14a),a third active layer (16) comprising impregnated or catalytic activated carbon particles (16a), wherein at least one active layer comprises impregnated activated carbon particles and the three active layers (12, 14, 16) differ from one another.The invention further discloses a filter media body including the filter medium; a filter element including the filter media body or the filter medium; an air filter including the filter element or the filter media body or the filter medium, and a production method for producing the filter medium.