Open-Cell Foam Air Filter with Sorbent Particles
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Solution Overview
Problem
Existing air purification methods are not universally applicable and inefficient in removing pollutants and odors from indoor environments, particularly due to their limited range of application and inability to effectively address secondary emission sources.
Innovation Solution
A mat-shaped foam material with a gas-permeable, open-cell structure loaded with sorption particles, such as activated carbon, is used for air filtration and purification, suitable for installation in ceilings, walls, and ventilation systems, providing a high adsorption capacity and efficient air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional air purification methods are used, then some pollutants can be removed, but they are not universally applicable and inefficient in removing pollutants and odors from indoor environments
Solution Approach 1:
The foam material is designed to simultaneously remove multiple types of pollutants including PCBs, VOCs, formaldehyde, and odors through a single integrated system. The open-cell foam structure combined with sorption particles creates a universal air purification solution that addresses various pollutant sources (primary and secondary emission sources) with one material, eliminating the need for multiple specialized filtration systems.
2Duration of action of moving object
If adsorbents are used in traditional configurations, then pollutant removal occurs, but the breakthrough time is limited and regeneration is difficult
Solution Approach 1:
The patent utilizes an open-cell foam structure with high porosity that allows deep penetration of air streams and pollutants throughout the material volume. This porous configuration significantly extends breakthrough time compared to traditional dense adsorbent layers. The open-cell structure also facilitates easier regeneration by allowing thorough penetration of regenerating agents (steam, hot air, or chemical solutions) through the entire material matrix.
Solution Approach 2:
The invention combines foam material with sorption particles to create a composite air purification material. The foam provides the porous matrix and structural framework, while the sorption particles (such as activated carbon, zeolites, or molecular sieves) provide the adsorption functionality. This composite structure extends breakthrough time by distributing the adsorption capacity throughout the three-dimensional foam structure and enables easier regeneration compared to traditional activated carbon filters.
3Quantity of substance
If traditional filtration materials are used, then air can be filtered, but they lack high adsorption capacity and efficient air permeability simultaneously
Solution Approach 1:
The open-cell foam structure provides interconnected pores that allow high air permeability while maintaining three-dimensional distribution of sorption particles. The porous matrix enables air to flow efficiently through the material without significant pressure drop, while the high surface area of the foam structure provides extensive support for sorption particles, achieving both high adsorption capacity and efficient air permeability simultaneously.
Solution Approach 2:
The composite of foam material and sorption particles creates a material that combines the high permeability of foam structures with the high adsorption capacity of sorption particles. The foam provides open pathways for air flow while the distributed sorption particles capture pollutants, achieving both high adsorption capacity and efficient air permeability that neither material could achieve alone.
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 foam material effectively reduces pollutant and odor concentrations, offering universal applicability and long-lasting adsorption performance, with breakthrough times exceeding several hours, and can be easily regenerated for reuse.
Implementation Method 1
an odor- and/or pollutant-sorbing material is incorporated and/or provided in the carrier, the odor- and/or pollutant-sorbing material being designed as an odor- and/or pollutant-sorbing, in particular odor- and/or pollutant-adsorbing, sorbent based on specific sorption particles
Data Source
Figure 1A~1B
AI summary
The invention relates to a mat-shaped foam material which is particularly suitable for cleaning and/or filtering air and, preferably, can be incorporated into ceilings and ceiling systems, walls and wall systems, air conditioning units, and ventilation shafts or can be used as a construction material or the like. The mat-shaped foam material comprises a gas-permeable, especially air-permeable, mat-shaped three-dimensional support that is designed as an open-cell or open-pore foam, particularly plastic foam. A material that sorbs odors and/or harmful substances is accommodated or provided in the support. Said material is designed as a sorbent which sorbs, particularly adsorbs, odors and/or harmful substances and is based on discrete sorption particles that are attached to the support, especially the walls of the cells or pores of the foam, particularly of the plastic foam.