Reticulated Foam Air Filter with Non-Toxic Tackified Coating
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Solution Overview
Problem
Reticulated foam air filters coated with tackified substances often outgas toxic substances, making them unsuitable for human respiration and posing health risks.
Innovation Solution
A non-toxic, odorless, biodegradable, and washable tackified coating is applied to reticulated foam filters using a dimer acid and distilled tall oil emulsion with an acidic aqueous carrier, ensuring the coating does not outgas and maintains tackiness for effective filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tackified coating is applied to reticulated foam filters to improve filtration characteristics, then filtering efficiency is improved, but toxic substances outgas making the filter unsuitable for human respiration
Solution Approach 1:
The patent changes the chemical composition parameters of the coating by using natural resinous materials (rosin, tall oil) instead of conventional synthetic tackifiers. This parameter change maintains the required tackiness for particle capture while eliminating toxic outgassing, making the filter safe for respiratory applications.
Solution Approach 2:
The patent creates a composite coating system combining multiple natural materials (rosin, tall oil, oils, waxes) that work synergistically to provide both the necessary adhesive properties for filtration and biocompatibility for respiratory use, avoiding toxic substances while maintaining performance.
2Manufacturing precision
If a coating is applied to achieve penetration into the heart of the foam, then filtration performance is improved, but the coating may result in toxic outgassing
Solution Approach 1:
The patent modifies the coating formulation parameters to use natural resinous materials that achieve adequate penetration into the foam structure without containing toxic substances, thereby eliminating harmful emissions while maintaining effective particle capture throughout the filter depth.
3Productivity
If the filter is designed for extended life and reusability, then productivity is improved, but maintaining performance without significant pressure drop becomes difficult
Solution Approach 1:
The patent optimizes the coating viscosity and application parameters to create a thin, uniform layer that provides effective filtration without excessive thickness. This parameter optimization ensures extended filter life through reusability while minimizing pressure drop to maintain energy efficiency during operation.
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 coated filters are safe for respiration, offer high efficiency in particle filtration, and can be reused, reducing waste and energy consumption by maintaining performance without significant pressure drop, thus providing extended filter life and cost savings.
Implementation Method 1
a non-toxic, odorless, biodegradable, and washable tackified coating is applied to reticulated foam filters using a dimer acid and distilled tall oil emulsion
Implementation Method 2
The coated filters are safe for respiration, offer high efficiency in particle filtration
Data Source
AI summary
A coated, reticulated foam air filter for filtering air suitable for respiration is described. The air filter comprises a reticulated foam structure and a nontoxic tackified coating applied to a functional surface of the foam structure.