Unbreakable Micro-Electrostatic Filter Sealing
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Solution Overview
Problem
Micro-electrostatic air purifiers face instability and efficiency decline in high-humidity environments due to current leakage, arcing, and sparking caused by poor sealing and exposure of electrodes in existing micro-electrostatic filters, leading to potential fire hazards.
Innovation Solution
A method for preparing an unbreakable micro-electrostatic filter involves drying and secondary granulation of insulating dielectric materials, forming a frame with air channels, arranging conductive material, and using hot-melt cutting with a heating wire to create a completely sealed filter, preventing electrode exposure and ensuring stability in humid conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional micro-electrostatic filters are used in high-humidity environments, then the filter structure is simple and easy to manufacture, but the filter suffers from current leakage, arcing, sparking, and efficiency decline
Solution Approach 1:
The patent applies nesting by placing the electrode slice inside the hollow microporous channel formed by the dielectric material, which is itself wrapped around the electrode. This nested structure ensures the electrode is completely enclosed and protected from humidity-related damage while maintaining a compact design. The ion generator is also nested within the filter assembly, creating a integrated unit that improves reliability without significantly increasing external dimensions.
Solution Approach 2:
The patent uses a dielectric material wrapped in the form of a thin film or shell around the electrode slice. This flexible wrapping creates a sealed hollow microporous channel that completely encloses the electrode, preventing current leakage and arcing in high-humidity environments. The thin film structure maintains simplicity while providing robust protection against environmental factors.
2Reliability
If the dielectric material is not effectively sealed, then the manufacturing process is simple, but electrodes are exposed leading to current leakage, arcing, and sparking
Solution Approach 1:
The electrode slice is nested within the hollow microporous channel formed by the dielectric material wrapping. This nested configuration naturally provides sealing as the dielectric wall completely surrounds the electrode, eliminating the need for additional sealing steps while ensuring electrodes cannot be exposed.
Solution Approach 2:
The dielectric material is applied as a continuous wrapping film around the electrode slice, forming a sealed hollow structure. This film-based approach ensures complete enclosure of the electrode with inherent sealing properties, preventing current leakage and arcing without requiring complex sealing mechanisms.
3Ease of manufacture
If the filter structure is simplified for ease of manufacture, then production is easier, but the filter becomes prone to damage and burning out in high-humidity environments
Solution Approach 1:
The dielectric material is wrapped around the electrode slice in a flexible hollow microporous channel structure. This wrapping provides inherent protection and reinforcement to the electrode, preventing damage and burning out in high-humidity environments while maintaining manufacturing simplicity through the straightforward wrapping process.
Solution Approach 2:
The filter employs a composite structure combining the dielectric material with the electrode slice and hollow microporous channel formation. This composite design provides enhanced strength and damage resistance to the electrode while maintaining ease of manufacture through the integrated wrapping process that creates a protective structure.
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 the sealing performance of micro-electrostatic filters, preventing current leakage, arcing, and sparking, ensuring stable operation and efficiency in high-humidity environments and reducing the risk of fire accidents.
Implementation Method 1
heating a heating wire to a preset temperature, and hot-melt cutting a micro-electrostatic filter with a required size out of the filter mold base
Implementation Method 2
hot-melt cutting a micro-electrostatic filter with a required size out of the filter mold base
Implementation Method 3
a strong electric field exerts a tremendous attraction on charged particles in the air, while such microorganisms attached to the particles as bacteria and viruses can be collected and killed in the strong electric field
Implementation Method 4
drying granular insulating dielectric raw materials with a box dryer
Data Source
AI summary
Disclosed is a method for preparing an unbreakable micro-electrostatic filter, which comprises: using raw materials obtained by the secondary granulation, cutting after extrusion moulding to obtain an electrode material isolating and carrying frame, arranging an interval-retaining spacer between the upper panel and the lower panel of the electrode material isolating and carrying frame, arranging a strip-shaped conductive material with a preset size on a surface of the electrode material isolating and carrying frame at regular interval in a direction perpendicular to the quadrilateral air channel to obtain a basic filtering plate, then stacking basic filtering plates to form a filter mold base, hot-melt cutting a micro-electrostatic filter with a required size out of the filter mold base through relative movement of the filter mold base and the heating wire, wherein each edge of the micro-electrostatic filter is subjected to hot-melt cutting, to form a micro-electrostatic filter with completely sealed electrodes.