Air Filtration Media with Intermittent Latex Additive Shapes
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Solution Overview
Problem
Current air filtration technologies face issues with microbial growth on filters, leading to odor problems and reduced lifespan, as well as interference with airflow and filtration performance due to the incorporation of additives, which can be encapsulated or affect the curing process.
Innovation Solution
The method involves printing intermittent geometric shapes of a latex base containing enhanced additives, such as antimicrobial and odor control agents, onto the filtration media, allowing controlled thickness and minimal impact on airflow, using aqueous latex and various curing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additives are mixed into the binder of the fibers, then the additives can be incorporated into the filtration media, but the binder may encapsulate the additives rendering them ineffective and adversely impact the curing of the binder
Solution Approach 1:
The invention segments the additive incorporation process by applying additives to the filtration media surface after the binder is set, rather than mixing them into the binder. This is achieved through a multi-step process: (1) applying the binder solution to the filtration media, (2) allowing the binder to set partially, (3) then applying the additive-containing composition to the surface. This segmentation prevents the binder from encapsulating the additives, ensuring they remain effective.
Solution Approach 2:
The invention performs preliminary action by applying the binder solution first and allowing it to set before applying the additive-containing composition. This preliminary application of the binder creates a foundation that prevents subsequent encapsulation of the additives, while the additive composition is applied in a controlled manner to ensure effectiveness.
2Quantity of substance
If additives are incorporated directly into the fiber during extrusion, then the additives can be integrated into the filtration media, but the additives can be encapsulated and rendered ineffective or interfere with the extrusion process
Solution Approach 1:
The invention segments the manufacturing process into distinct stages: (1) fiber formation without additives, (2) partial setting of the binder, (3) application of additive-containing composition to the surface. This segmentation allows the extrusion process to proceed without interference from additives, while still achieving effective additive incorporation through the subsequent surface application.
3Quantity of substance
If silane based coatings containing additives are applied directly onto the fabrics, then the additives can be applied to the filtration media, but the coating wets the entire fabric and plugs the pores affecting filtration performance
Solution Approach 1:
The invention applies local quality by using a printing or coating process that deposits the additive-containing composition only on the surface of the filtration media rather than wetting the entire fabric. This localized application ensures additives are applied where needed while preserving the porous structure and filtration performance of the media.
Solution Approach 2:
The invention respects the porous nature of the filtration media by applying the additive-containing composition in a manner that does not plug the pores. The composition is applied to the surface while maintaining the open structure necessary for filtration, thus preserving the media's porous characteristics and airflow properties.
4Quantity of substance
If the entire surface of the fabric is coated with silane based coatings, then the additives can be applied uniformly, but the coating increases resistance to airflow and interferes with electrostatic treatments
Solution Approach 1:
The invention applies local quality by using a printing or selective coating process that deposits the additive-containing composition only on the surface of the filtration media rather than coating the entire fabric. This localized application maintains airflow resistance at acceptable levels while providing adequate additive distribution for effectiveness.
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 approach effectively prevents microbial growth, maintains airflow efficiency, and enhances particle removal efficiency while providing odor control without compromising filtration performance.
Implementation Method 1
The intermittent geometric shapes can be applied to the filtration media by a printing process. The latex base contains enhanced additives such as antimicrobial agents and odor control agents that are deposited on the filtration media surface through the printing process.
Implementation Method 2
The intermittent geometric shapes are applied in an aqueous latex base and then cured on the filtration media by heating, chemical reaction, U.V. curing or other known methods.
Data Source
AI summary
An air filter that includes a filtration material having at least one surface, an enclosed frame surrounding said filter material but exposing said one surface, said filter material having intermittent geometric shapes of latex on said at least one surface, said latex containing an enhanced additive.