Humidifier Disk Lattice Grooves for Higher Water Adsorption
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Solution Overview
Problem
Existing humidifier disks face challenges in maximizing water adsorption capacity while maintaining productivity and reducing manufacturing costs, as larger or more numerous disks increase product size, weight, and complexity, leading to low water adsorption and delamination issues with coatings.
Innovation Solution
A disk with a fine lattice-shaped groove pattern on both surfaces, featuring inclined and interconnected grooves forming diamond-shaped protrusions, which enhances water adsorption and is manufactured using injection molding with a corresponding mold, reducing the need for post-processing and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the disk size and number are increased to secure humidification amount, then the water adsorption capacity is improved, but the product size, weight, and manufacturing complexity increase
Solution Approach 1:
The disk surface is segmented into multiple lattice-shaped grooves that create numerous small protrusions. This segmentation increases the total surface area for water adsorption without increasing the overall disk size, allowing more water to be held on the same disk area through divided surface structures.
Solution Approach 2:
The invention transitions from a flat disk surface to a three-dimensional lattice pattern with grooves and protrusions. This dimensional change creates vertical depth in the surface structure, increasing the effective adsorption area without expanding the disk's horizontal footprint, thus improving water capacity while maintaining compact size.
2Quantity of substance
If the disk size and number are increased to secure humidification amount, then the water adsorption capacity is improved, but the product weight increases
Solution Approach 1:
By dividing the disk surface into lattice grooves and protrusions, the invention maximizes water adsorption on a single disk rather than requiring multiple larger disks. This segmentation allows one lightweight disk to replace several heavier disks, reducing overall product weight while maintaining water capacity.
Solution Approach 2:
The lattice pattern creates vertical depth through grooves and protrusions, increasing adsorption capacity in the vertical dimension rather than expanding horizontal disk area. This allows the same water capacity to be achieved with smaller, lighter disks instead of larger, heavier ones.
3Quantity of substance
If the disk surface is coated to improve hydrophilic property, then the water adsorption amount is improved, but the coating delaminates to generate floating materials
Solution Approach 1:
The invention extracts the hydrophilic function from a separate coating layer and integrates it directly into the disk's base structure through lattice-shaped grooves. This eliminates the coating layer that would otherwise delaminate, while maintaining water adsorption capability through the geometric lattice pattern that inherently promotes water retention.
Solution Approach 2:
The lattice pattern creates a composite structure where the groove geometry itself provides the water-retention function that would otherwise require a hydrophilic coating. This structural composite replaces the material composite of disk-plus-coating, eliminating delamination while preserving water adsorption.
4Quantity of substance
If a complex structure with ribs and patterns is used to retain moisture, then the water adsorption amount is improved, but the molding process becomes complex
Solution Approach 1:
The lattice pattern is segmented into repeating unit cells of grooves and protrusions that can be efficiently formed using standard injection molding techniques. This regular segmentation allows the complex surface structure to be manufactured through simple mold cavity design, avoiding complex multi-step molding processes.
Solution Approach 2:
The invention optimizes the lattice parameters (groove depth, width, spacing, and angle) to achieve maximum water adsorption within the constraints of standard molding capabilities. By adjusting these parameters, the design achieves high water capacity while remaining compatible with conventional injection molding processes, avoiding the need for complex or specialized manufacturing.
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 lattice pattern significantly increases water adsorption capacity and maintains it over time, while allowing for mass production with reduced manufacturing costs and improved humidification performance.
Implementation Method 1
a fine pattern having a lattice-shaped groove defined in a surface of the disk for the humidifier and a protrusion defined by the groove and protruding from the surface of the disk
Data Source
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AI summary
A disk for a humidifier and a method for manufacturing the same are provided. A fine pattern defined by grooves having a lattice shape, onto which moisture is adsorbed, is provided on both entire surfaces of a disk of a vaporizing humidifier to increase a water adsorption amount and improve productivity.