Spun-Yarn Discharge Electrode for Low-Ozone Aerosol Ionization
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Solution Overview
Problem
Existing aerosol ionization devices using metal wires as discharge electrodes face issues such as high ozone generation, reduced discharge efficiency due to contamination, increased component count, and elevated manufacturing costs, primarily due to complex manufacturing processes and susceptibility to deformation.
Innovation Solution
The use of a discharge electrode composed of a spun yarn made from electrically-conductive metal staple fibers, such as stainless steel, with protruding ends, which reduces ozone generation, simplifies manufacturing, and decreases contamination-related inefficiencies by allowing easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If metal wires are used as discharge electrodes, then discharge efficiency is maintained, but ozone generation increases and contamination occurs
Solution Approach 1:
The invention changes the physical parameters of the discharge electrode from solid metal wires to a spun yarn structure with porous characteristics. This structural parameter change reduces the surface area in direct contact with air, thereby reducing ozone generation while maintaining discharge efficiency through the protruding conductive fiber ends that create effective discharge points.
Solution Approach 2:
The discharge electrode is constructed as a composite material system combining conductive metal staple fibers (providing electrical conductivity for discharge) with insulating spun yarn matrix (providing structural support and reducing overall conductivity). This composite structure enables discharge functionality while minimizing harmful ozone generation through reduced exposed conductive surface area.
2Reliability
If metal wires are used as discharge electrodes, then discharge functionality is achieved, but susceptibility to deformation increases
Solution Approach 1:
The invention replaces rigid metal wires with a flexible spun yarn structure that can withstand deformation without damage. The spun yarn acts as a flexible matrix that protects the embedded conductive fibers, allowing the electrode to maintain its discharge functionality even when bent or deformed during installation and operation.
Solution Approach 2:
The composite structure of conductive fibers within an insulating yarn matrix provides both mechanical flexibility and electrical functionality. The yarn matrix absorbs mechanical stress and deformation, protecting the conductive fibers from damage while maintaining discharge pathways through the protruding fiber ends.
3Reliability
If complex manufacturing processes are used, then electrode performance is optimized, but manufacturing costs increase
Solution Approach 1:
The conductive metal staple fibers are naturally distributed within the spun yarn structure during manufacturing, with their protruding ends automatically forming the discharge surface. This self-organizing structure eliminates the need for complex post-processing steps to create discharge points, as the fibers naturally protrude during the spinning process, simplifying manufacturing while maintaining performance.
Solution Approach 2:
The invention changes the manufacturing approach from precision engineering of solid wires to a textile-based spun yarn process. This parameter change in the manufacturing method utilizes established textile spinning techniques to create the electrode structure, reducing manufacturing complexity and cost while the protruding fiber ends naturally provide the required discharge functionality.
4Stability of the object's composition
If solid discharge electrodes are used, then structural integrity is maintained, but contamination resistance decreases
Solution Approach 1:
The spun yarn structure inherently possesses a porous, fibrous morphology with numerous small channels and surfaces. This porous structure prevents continuous contamination films from forming on the discharge surface, as contaminants cannot easily adhere to the distributed fiber ends. The structure maintains structural integrity through the yarn matrix while providing contamination resistance through its porous, non-planar geometry.
Solution Approach 2:
The composite of conductive fibers and insulating yarn matrix creates a structure where the yarn matrix provides structural integrity and the fiber ends provide discharge functionality with inherent contamination resistance. The complex surface geometry of the protruding fibers within the yarn matrix prevents uniform contamination accumulation, maintaining discharge efficiency over time.
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 effectively charges aerosols with reduced ozone production, lowers manufacturing costs, and maintains discharge efficiency by minimizing contamination and component complexity.
Implementation Method 1
When a high voltage is applied between the discharge electrode and the counter electrode, corona discharge occurs at the discharge electrode. Aerosol in the air is ionized by using ions generated around the discharge electrode.
Implementation Method 2
The discharge electrode includes a spun yarn including electrically-conductive metal staple fibers. Ends of at least some of the electrically-conductive metal staple fibers protrude from a surface of the spun yarn.
Data Source
AI summary
An aerosol ionization device including a discharge electrode and a counter electrode. The discharge electrode includes a spun yarn including electrically-conductive metal staple fibers. Ends of at least some of the electrically-conductive metal staple fibers protrude from a surface of the spun yarn. The counter electrode faces the discharge electrode with a gap therebetween.