Pattern Coated Filter Adsorbent Beads Integration

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Solution Overview

Problem

Existing filters for electronics enclosures, such as recirculation and breather filters, have complex manufacturing processes and limited adsorbent capacity, which can lead to inefficient contaminant removal and reduced component longevity in electronics enclosures.

Innovation Solution

A filter assembly with multiple layers, including a base layer and two filter layers, where adsorbent beads are strategically coupled to the layers using a patterned adhesive, increasing the adsorbent capacity and simplifying the manufacturing process by integrating adsorbent directly into the filter structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adsorbent is contained within filtration media, then chemical contaminants are adsorbed, but manufacturing process complexity increases

Engineering Contradiction:

Improvechemical contaminant removalVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the adsorbent material directly with the filtration media into a single integrated structure. The adsorbent-coated filtration media allows both particle filtration and chemical adsorption to occur within one component, eliminating the need for separate adsorbent containment structures and simplifying the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filtration media is designed to perform multiple functions simultaneously: it acts as both a particle filter and a chemical adsorbent. By coating the filtration media with adsorbent material, a single component provides both mechanical filtration and chemical contaminant removal, reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If adsorbent is contained within filtration media, then chemical contaminants are adsorbed, but manufacturing process complexity increases

Engineering Contradiction:

Improvechemical contaminant removalVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If traditional filter structure is used, then manufacturing is simpler, but adsorbent capacity is limited

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidadsorbent capacity

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent utilizes the porous structure of the filtration media to maximize adsorbent capacity. The coating process impregnates the adsorbent material into the porous network of the filtration media, allowing high adsorbent loading while maintaining the open structure needed for airflow and contaminant access.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent creates a composite material by combining the filtration media matrix with the adsorbent coating. This composite structure integrates the mechanical filtration properties of the base media with the chemical adsorption capabilities of the coating, achieving both high adsorbent capacity and manufacturing feasibility.

Inventive Principle:

Principle #40Composite materials

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 filter assembly effectively removes contaminants by increasing adsorbent capacity and streamlining the manufacturing process, enhancing the efficiency and longevity of electronics components by improving airflow filtration and chemical contaminant absorption.

Implementation Method 1

the adsorbent adsorbs chemical contaminants

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

The filtration media filters particle contaminants

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Data Source

PatentUS10780381B2Pattern coated filter and method

Publication Date: 2020.09.22 DONALDSON CO INC

AI summary

The present technology is generally related to a filter assembly. The filter assembly has a first layer has a base layer defining a first perimeter region and a region central to the first perimeter region. A first adhesive is disposed on a first surface of the first layer substantially within the central region, and first adsorbent beads are coupled to the first adhesive. A second layer has a first sheet of filter material having a second perimeter region, wherein the first perimeter region and the second perimeter region are bonded. A third layer has a second sheet of filter material having a third perimeter region, wherein the first perimeter region and the third perimeter region are bonded. The base layer, second layer, and third layer are substantially coextensive.