Hair dryer
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Solution Overview
Problem
Existing hair dryer filters suffer from dust and debris buildup, leading to reduced air pressure and overheating due to their design, causing cyclical cutting out of the hair dryer.
Innovation Solution
A metal filter plate with holes of less than 1.5 mm maximum lateral dimension and concave or straight walls is used, with a subset of hexagonally close-packed holes, reducing in size towards the edge, and aligned along spiral arms to match the impeller's velocity profile, facilitating improved airflow and ease of cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional filter (plastic injection moulding or metal mesh) is used, then the filter structure is simple and easy to manufacture, but dust and debris build up in the filter over time, reducing air pressure and causing overheating
Solution Approach 1:
The patent applies porous materials by using a filter plate with numerous small holes (maximum lateral dimension less than 1.5mm) arranged in a specific pattern. The porous structure allows air to pass through while effectively filtering debris, and the concave walls create turbulence that prevents particle accumulation. This resolves the contradiction by providing reliable air flow consistency through the porous design while maintaining manufacturability via standard drilling and shaping processes.
Solution Approach 2:
The patent employs curvature by designing the hole walls with concave sections rather than straight cylindrical walls. The concave geometry creates turbulent flow patterns that prevent dust and debris from settling on the hole surfaces. This curved wall design improves reliability by preventing clogging while remaining compatible with conventional manufacturing methods such as electrical discharge machining or laser drilling.
2Productivity
If the filter holes are larger, then air flow is improved, but debris can pass through the filter and enter the motor
Solution Approach 1:
The patent applies local quality by varying the hole dimensions and distribution pattern across different regions of the filter plate. Holes are positioned and sized to match the local air flow velocity profile, with higher density in regions requiring better filtration and appropriate spacing in regions requiring higher flow rates. This localized optimization allows the filter to maintain small hole sizes for debris prevention while achieving adequate overall air flow productivity.
Solution Approach 2:
The patent changes physical parameters by specifying that hole maximum lateral dimensions be less than 1.5mm (preferably less than 1mm) and the filter plate thickness be less than 0.5mm (approximately 0.3mm). These parameter changes enable small holes that block debris while the concave wall geometry and optimized hole pattern maintain sufficient air flow rate, resolving the contradiction between filtration effectiveness and air flow productivity.
3Ease of manufacture
If the filter plate is thicker, then manufacturing is easier, but the holes require more material removal and cleaning complexity increases
Solution Approach 1:
The patent applies curvature by designing concave hole walls that taper or curve inward from the outer surface toward the inner surface of the filter plate. This concave geometry prevents debris from accumulating on the inner walls and makes hole cleaning simpler, as particles are less likely to adhere to the curved surfaces. The design maintains ease of manufacture by using standard thin plate materials (less than 0.5mm thick) while reducing cleaning complexity through the self-cleaning effect of the concave geometry.
4Productivity
If the holes are arranged in a uniform pattern, then manufacturing is simpler, but the air flow velocity profile is not optimized
Solution Approach 1:
The patent applies local quality by arranging holes in non-uniform patterns that match the local air flow velocity profile. The hole distribution density, size, and orientation are optimized for different regions of the filter plate based on the impeller-induced flow characteristics. This localized optimization improves air flow efficiency by reducing turbulence and pressure losses while the overall pattern remains manufacturable using standard hole-making processes.
Solution Approach 2:
The patent employs curved or spiral patterns for hole arrangement rather than simple straight-line or grid patterns. The holes are positioned along curved trajectories that follow the natural air flow paths created by the impeller, reducing flow separation and turbulence. This curved pattern design improves air flow efficiency while maintaining reasonable manufacturing complexity by using conventional drilling and positioning methods.
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 solution enhances airflow, reduces noise, and prevents debris accumulation, ensuring consistent air pressure and preventing overheating, thus maintaining the hair dryer's performance.
Implementation Method 1
walls of said holes through a thickness of said filter plate are substantially straight or at least partially concave
Data Source
AI summary
A hair dryer (10) has a hand-held housing comprising an air inlet (12), an air outlet (14), a motor (1) between said air inlet (12) and said air outlet (14) to draw air in from said air inlet (12) and drive air out from said air outlet (14). A heating element (17) is located in said air flow between said air inlet (12) and said air outlet (14). The hair dryer (10) further comprises a filter on said air inlet (12). The filter comprises a metal filter plate (20) bearing a plurality of holes, wherein at least some of said holes have a maximum lateral dimension of less than 1.5 mm and wherein vertical walls of said holes through a thickness of said filter plate are substantially straight or at least partially concave.