Air filter comprising a multilayer filter material

Patent metadata

Field	Value
Publication number	US-10695705-B2
Application number	US-201716085840-A
Country	US
Kind code	B2
Filing date	Mar 7, 2017
Priority date	Mar 18, 2016
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

A multilayer filter material for an interior air filter element of an air conditioning system of a vehicle may include an ion exchange layer including ion exchange particles and a plurality of further layers. The ion exchange layer may directly adjoin at least one of the plurality of further layers. The plurality of further layers may include an active layer including non-impregnated active carbon particles, and an impregnation layer including impregnated active carbon particles. The active layer may be arranged between the ion exchange layer and the impregnation layer. The ion exchange layer may be hygroscopic and may contain ions which form a toxic environment with water. The impregnation layer may include a component of active carbon particles impregnated with potassium iodide and a component of active carbon particles impregnated with potassium carbonate. The component impregnated with potassium iodide may be greater than the component impregnated with potassium carbonate.

First claim

The invention claimed is:

1. A multilayer filter material for an interior air filter element of an air conditioning system of a vehicle, comprising:
an ion exchange layer including ion exchange particles;
a plurality of further layers;
the ion exchange layer directly adjoining at least one of the plurality of further layers;
the plurality of further layers including an active layer, which includes non-impregnated active carbon particles, and an impregnation layer, which includes impregnated active carbon particles;
the active layer arranged between the ion exchange layer and the impregnation layer;
wherein the ion exchange layer is hygroscopic and contains ions which form a toxic environment with water;
wherein the impregnation layer includes a component of active carbon particles impregnated with potassium iodide and a component of active carbon particles impregnated with potassium carbonate; and
wherein a weight % of the impregnation layer provided by the component impregnated with potassium iodide is greater than a weight % of the impregnation layer provided by the component impregnated with potassium carbonate.

2. The filter material according to claim 1 , wherein the ion exchange layer includes acid ions which form an acid environment with water.

3. The filter material according to claim 1 , wherein the ion exchange layer includes cation exchange particles.

4. The filter material according to claim 1 , wherein the ion exchange layer includes ion exchange particles including sulphonic acid groups.

5. The filter material according to claim 1 , wherein the ion exchange particles are at least partially fibrous and are incorporated into a non-woven material layer including filter material fibres.

6. The filter material according to claim 1 , wherein the ion exchange particles are at least partially pulverulent and are incorporated into a non-woven material layer including filter material fibres.

7. The filter material according to claim 1 , wherein at least one of:
the active layer has an ash content of 5% by weight or less; and
the active layer includes active carbon particles having a grain size of at least one of 30×60 mesh and 30×70 mesh.

8. The filter material according to claim 1 , wherein the impregnation layer contains approximately 10% by weight of the component impregnated with potassium iodide and approximately 5% by weight of the component impregnated with potassium carbonate.

9. The filter material according to claim 1 , wherein the active layer on one side directly adjoins the impregnation layer and on another side directly adjoins the ion exchange layer.

10. The filter material according to claim 1 , wherein:
the impregnation layer includes a non-woven material of filter material fibres and forms an outer side of the filter material;
the ion exchange layer includes a non-woven material of filter material fibres and forms another outer side of the filter material; and
the filter material includes only the ion exchange layer, the active layer and the impregnation layer.

11. The filter material according to claim 1 , wherein:
the plurality of further layers further includes two additional layers;
the ion exchange layer on one side directly adjoins the active layer and on another side directly adjoins a first additional layer;
the impregnation layer on one side directly adjoins the active layer and on another side directly adjoins a second additional layer; and
the filter material consists of the ion exchange layer, the active layer, the impregnation layer and the two additional layers.

12. The filter material according to claim 1 , wherein:
the plurality of further layers further includes three additional layers;
the ion exchange layer on one side directly adjoins a first additional layer;
the impregnation layer on one side directly adjoins the active layer and on another side directly adjoins a second additional layer;
the ion exchange layer on another side directly adjoins a third additional layer, which directly adjoins the active layer; and
the filter material consists of the ion exchange layer, the active layer, the impregnation layer and the three additional layers.

13. The filter material according to claim 1 , wherein:
the plurality of further layers further includes four additional layers;
the ion exchange layer on one side directly adjoins a first additional layer;
the impregnation layer on one side directly adjoins a second additional layer;
the ion exchange layer on another side directly adjoins a third additional layer;
the impregnation layer on another side directly adjoins a fourth additional layer;
the active layer on one side directly adjoins the third additional layer and on another side directly adjoins the fourth additional layer; and
the filter material consists of the ion exchange layer, the active layer, the impregnation layer and the four additional layers.

14. The filter material according to claim 11 , wherein at least one of:
at least one of the two additional layers is configured as a support layer which is penetrable by particles having a grain size of less than 1 mm; and
at least one of the two additional layers is configured as a particle filter layer which is impenetrable by particles having a grain size of greater than 0.1 mm.

15. The filter material according to claim 1 , wherein the ion exchange layer, with respect to a throughflow direction of the filter material in an installed state, is arranged upstream of the impregnation layer.

16. An interior air filter element for an air conditioning system of a vehicle, comprising a filter body and a filter material, the filter material including:
a hygroscopic ion exchange layer including ion exchange particles and ions which form a toxic environment with water;
a plurality of further layers including an active layer and an impregnation layer, at least one of the plurality of further layers directly adjoining the ion exchange layer, the active layer including non-impregnated active carbon particles and arranged between the ion exchange layer and the impregnation layer, the impregnation layer including impregnated active carbon particles, a component of active carbon particles impregnated with potassium iodide, and a component of active carbon particles impregnated with potassium carbonate; and
wherein a weight % of the impregnation layer provided by the component impregnated with potassium iodide is greater than a weight % of the impregnation layer provided by the component impregnated with potassium carbonate.

17. The interior air filter element according to claim 16 , wherein the ion exchange layer, with respect to a throughflow direction of the filter material in an installed state, is arranged upstream of the impregnation layer.

18. An air conditioning system for a vehicle, comprising an interior air filter device including at least one interior air filter element, the at least one interior air filter element including a filter body and a filter material, the filter material including:
a hygroscopic ion exchange layer including ion exchange particles and ions which form a toxic environment with water;
a plurality of further layers including an active layer and an impregnation layer, at least one of the plurality of further layers directly adjoining the ion exchange layer, the active layer including non-impregnated active carbon particles and arranged between the ion exchange layer and the impregnation layer, the impregnation layer including impregnated active carbon particles, the impregnated active carbon particles

Assignees

• Mahle Int Gmbh

Inventors

• Hein Martin
• Merz Katharina
• Renz Birgit

Classifications

• B01D2253/25

  Coated, impregnated or composite adsorbents · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B01D2239/0442

  Antimicrobial, antibacterial, antifungal additives · CPC title

• B01D39/1623

  of synthetic origin · CPC title

• B32B2264/108

  Carbon, e.g. graphite particles · CPC title