ELECTROSTATIC FILTER UNIT FOR AN AIR CLEANING DEVICE AND AIR CLEANING DEVICE

Abstract

An electrostatic filter unit for an air cleaning device includes an ionization unit for charging a particle contained in an air flow, a separation unit arranged downstream of the ionization unit in a direction of flow of the air, with the separation unit including at least two collecting electrodes which are air-permeable, and a protection element for at least one element of the ionization unit.

Claims

1-14. (canceled)

15. An electrostatic filter unit for an air cleaning device, said electrostatic filter unit comprising: an ionization unit for charging a particle contained in an air flow; a separation unit arranged downstream of the ionization unit in a direction of flow of the air, said separation unit including at least two collecting electrodes, said at least two collecting electrodes being air-permeable; and a protection element for at least one element of the ionization unit.

16. The electrostatic filter unit of claim 15, wherein the protection element is embodied as a screening element configured to provide protection against an effect of force.

17. The electrostatic filter unit of claim 15, wherein the protection element is embodied as an intervention protection device which includes a layer and is connected upstream of the ionization unit in the direction of flow.

18. The electrostatic filter unit of claim 17, wherein the layer is embodied as a prefilter.

19. The electrostatic filter unit of claim 18, wherein the intervention protection device includes a protection layer and a spacer element, said spacer being arranged between the prefilter and the protection layer.

20. The electrostatic filter unit of claim 15, wherein the protection element includes at least partially an electrically conductive or antistatic element having a surface resistance R<=10.sup.11 Ohms.

21. The electrostatic filter unit of claim 15, wherein the protection element is configured to form a part of a housing of the ionization unit.

22. The electrostatic filter unit of claim 21, further comprising a high-voltage transformer integrated in the part of the housing.

23. The electrostatic filter unit of claim 18, further comprising a high-voltage transformer integrated in a part of a housing of the ionization unit, wherein the prefilter is connected to a return of a secondary side of the high-voltage transformer.

24. The electrostatic filter unit of claim 23, further comprising a filter frame connected to the return of the secondary side of the high-voltage transformer.

25. The electrostatic filter unit of claim 15, wherein the at least two collecting electrodes lie perpendicular to the direction of flow of the air through the ionization unit.

26. The electrostatic filter unit of claim 15, wherein at least one of the at least two collecting electrodes has an insulation coating.

27. The electrostatic filter unit of claim 15, wherein one of the at least two collecting electrodes is a positive collecting electrode which has an insulation coating.

28. An air cleaning device, comprising an electrostatic filter unit, said electrostatic filter unit comprising an ionization unit for charging a particle contained in an air flow, a separation unit arranged downstream of the ionization unit in a direction of flow of the air, said separation unit including at least two collecting electrodes, said at least two collecting electrodes being air-permeable, and a protection element for at least one element of the ionization unit.

29. The air cleaning device of claim 28, constructed in the form of an extractor hood, said extractor hood having a contact point for contact to a high-voltage transformer of the filter unit.

Description

[0042] The invention is described again in the following with reference to the appended figures, in which:

[0043] FIG. 1 shows a schematic perspective view of an embodiment of an air cleaning device according to the invention;

[0044] FIG. 2 shows a schematic exploded diagram of an embodiment of an electrostatic filter unit according to the invention;

[0045] FIG. 3 shows a schematic exploded diagram of the intervention protection device of the electrostatic filter unit according to FIG. 2;

[0046] FIG. 4 shows a schematic exploded diagram of the ionization unit of the electrostatic filter unit according to FIG. 2;

[0047] FIG. 5 shows a schematic exploded diagram of the separation unit of the electrostatic filter unit according to FIG. 2;

[0048] FIGS. 6a and 6b show schematic perspective views of embodiment of the collecting electrodes of the electrostatic filter unit according to FIG. 2;

[0049] FIG. 7 shows a schematic sectional view of an embodiment of the collecting electrodes of the electrostatic filter unit according to the invention;

[0050] FIGS. 8a and 8b show schematic sectional views of further embodiment of the collecting electrodes of the electrostatic filter unit according to the invention;

[0051] FIG. 9 shows a schematic diagram of the cabling of an embodiment of the electrostatic filter unit according to the invention; and

[0052] FIG. 10 shows a schematic diagram of the filter efficiency of the electrostatic filter unit according to the invention in comparison with expanded metal filters.

[0053] FIG. 1 shows an embodiment of an air cleaning device 1 according to the invention. In the embodiment shown, the air cleaning device 1 takes the form of an extractor hood. In the embodiment shown, a suction opening in which are arranged two electrostatic filter units 2 is formed in the front side of the air cleaning device 1. It is however also within the scope of the invention for only one or more than two electrostatic filter units 2 to be arranged in the suction opening. An air outlet connection piece 3 for the air exit from the air cleaning device 1 is provided in the top side of the air cleaning device. In the embodiment shown, the suction opening and therefore the electrostatic filter units 2 are oriented vertically. It is however also within the scope of the invention for the suction opening and therefore the electrostatic filter units 2 to be oriented in any desired adjustment angle between the vertical and the horizontal. In the embodiment shown, the electrostatic filter units 2 have a cartridge format. The electrostatic filter units 2 are therefore also referred to as filter cartridges. In particular, the electrostatic filter units 2 have a width and length which is greater than their depth in each case. Depth in this context refers to the dimension in the main direction of flow, which is horizontal in the embodiment shown. The main direction of flow is indicated by a block arrow in the figures. The electrostatic filter units 2 cover the suction opening completely. This means that all of the air arriving at the air cleaning device 1 is routed through the electrostatic filter units 2. During operation of the air cleaning device, the impure air flows through the planar surface areas of the electrostatic filter units 2 and by means of the electrostatic and mechanical filter mechanisms is purified of liquid and solid impurities/particles, in particular those having a hydraulic diameter D.sub.hyd>=0.001 μm, as a result of filtering. When the electrostatic filter units 2 have reached their saturation level in respect of impurities, they can be removed from the air cleaning device and cleaned in the dishwasher or manually by hand using water and detergent.

[0054] FIG. 2 shows a schematic exploded diagram of an embodiment of an electrostatic filter unit 2 according to the invention. In the embodiment shown, the electrostatic filter unit 2 consists of a filter frame 40, an intervention protection device 60, an ionization unit 100 and a separation unit 170. These individual function modules of the electrostatic filter unit 2 have a plane format or define a surface area in each case. In the embodiment shown, the filter frame 40 consists of two parts. That part shown as the lower part in FIG. 2 is subsequently referred to as the filter frame front side 4 and that part of the filter frame 40 shown as the upper part is referred to as the filter frame rear side 5. For the purpose of manufacturing or assembling the electrostatic filter unit 2, the intervention protection device 60, the ionization unit 100 and the separation unit 170 can be placed into the filter frame front side 4 and then closed off using the filter frame rear side 5.

[0055] FIG. 3 shows the embodiment of the intervention protection device 60 in an exploded diagram. According to the present invention, the intervention protection device 60 forms a protection element. In the embodiment shown, the intervention protection device 60 consists of three individual parts. In particular, the intervention protection device 60 consists of a protection layer 6, a spacer element for intervention protection 7 and a filter layer for prefiltering 8, also referred to as a prefilter in the following. The individual parts of the intervention protection device 60 have a plane format or layer format in each case. The first layer, which forms the actual protection layer 6, protects the individual parts of the intervention protection device 60, and modules of the electrostatic filter unit 2 that are situated behind said first layer, from the effects of any improper external force. Furthermore, the protection layer 6 can enhance the visual effect of the overall filter cartridge as a design element. The protection layer 6 can be made from an electrically conductive material, in particular metal, or an electrically insulating material, in particular plastic.

[0056] In addition to the mechanical protection from the effect of force, the intervention protection device 60 can also serve as an electrical protection element. In particular, the filter layer for prefiltering 8 serves as an electrical protection element. The filter layer for prefiltering 8 serves firstly as a prefilter for relatively large particles of dirt and dust, in particular for particles where D.sub.hyd>=1 μm. Secondly, the filter layer for prefiltering 8 also serves as an electrical screen. In this context, the screening by the filter layer for prefiltering 8 takes place in accordance with the principle of a Faraday cage. In particular, the ionization unit 100 and the separation unit 170, which are situated behind the filter layer for prefiltering 8 in the direction of flow, are screened thereby. In particular, the filter layer for prefiltering 8 has the effect that the external intake zone, i.e. the zone in front of the electrostatic filter unit 2 in the direction of flow, remains free of fields owing to the static and quasistatic electrical fields of the ionization unit, and the resulting outward electrical influence, in particular beyond the protection layer 6, is prevented. Unwanted static charging of the protection layer 6 is thereby prevented. The filter layer for prefiltering 8 preferably consists of an air-permeable electrically conductive or antistatic material. For example, the filter layer for prefiltering can be manufactured from electrically conductive plastic. The filter layer for prefiltering 8 can however also consist of for example expanded metal, perforated sheet metal, wire cloth, welded mesh or woven wire netting. The filter layer for prefiltering 8 preferably has a surface resistance R<=10.sup.11 Ohms. In the embodiment shown, the filter layer for prefiltering 8 consists of only one layer. It is however also within the scope of the invention for the filter layer for prefiltering 8 to consist of more than one layer.

[0057] A further layer of the intervention protection device 60 is provided between the filter layer for prefiltering 8 and the protection layer 6. This is referred to as a spacer element for intervention protection 7 and serves to keep the filter layer for prefiltering 8 and the protection layer 6 at a defined distance from each other.

[0058] FIG. 4 shows an exploded view of an embodiment of the ionization unit 100 of the electrostatic filter unit 2. In the embodiment shown, the ionization unit 100 consists of an inner frame 9, two insulation housing parts 10, 11, counter electrodes 15 and ionization elements 16 which can also be referred to as emission electrodes. In the embodiment shown, provision is also made for spacers 12 which keep the counter electrodes 15 at a distance from each other. In the embodiment shown, the ionization unit 100 further comprises a high-voltage transformer 14 and a high-voltage bus bar 13.

[0059] The insulation housing parts 10 and 11 are inserted into the inner frame 9. The insulation housing parts 10, 11 each have the format of a rectangular bar and are inserted into the inner frame 9 at opposite ends, in particular longitudinal ends thereof. The insulation housing parts 10, 11 each have contact openings on one side in which the ionization elements 16 are placed. The insulation housing parts 10 and 11 are inserted into the inner frame 9 in such a way that the contact openings face towards each other. This means that the ionization elements 16, which can take the form of wires, can be suspended between the insulation housing parts 10, 11. The counter electrodes 15, which are formed by plates in the embodiment shown, are slotted into the inner frame 9 and preferably also into the insulation housing parts 10, 11. The spacers 12 are also installed, keeping the counter electrodes 15 at a distance from each other along their entire length. The insulation housing parts, 10, 11 preferably consist of an electrically insulating material and preferably have a surface resistance R>=10.sup.11 Ohms. The insulation housing parts 10, 11 preferably consist of ceramic or plastic.

[0060] In one of the insulation housing parts 10, 11 in the embodiment shown, a mounting frame is also provided in the insulation housing part 11. In the mounting frame are provided the high-voltage transformer 14, the high-voltage bus bar 13 and various cabling elements and contacts (not shown) which are required for the electrical contacting of the relevant individual parts. The ionization elements 16 are then secured between the insulation housing parts 10, 11 and in particular between the high-voltage bus bar 13 of the insulation housing part 11 and the insulation housing part 10.

[0061] FIG. 5 shows an embodiment of the separation unit 170 of the electrostatic filter unit 2. The separation unit 170 is constructed from negative collecting electrodes 17, separation unit spacer elements 18 and positive collecting electrodes 19. The spacer elements 18 keep the positive collecting electrodes 19 and negative collecting electrodes 17 at a defined distance from each other. The positive collecting electrodes 19 are preferably exposed to a high voltage U>1 kV DC (direct current). The positive collecting electrodes 19 are preferably completely electrically insulated with an electrically insulating cover as far as the contact points 20, in order to prevent electric arcing and short circuits. For the purpose of insulation, the positive collecting electrodes 19 can be coated. Possible coating methods include functional powder coating, fluidized-bed coating, sol-gel, dip-coating, enameling or painting. An electrically conductive material, in particular metal, is preferably used as a base material or substrate for the positive collecting electrodes 19. Particularly preferably, the materials shown in FIGS. 6a and 6b can be used as a substrate for the positive collecting electrodes 19. In the embodiment variant according to FIG. 6a, the substrate takes the form of perforated sheet metal or expanded metal, and according to FIG. 6b a welded mesh.

[0062] As an alternative to metal, it is also possible to use electrically conductive or antistatic plastics having a surface resistance R<=10.sup.11 Ohms for the substrate of the positive collecting electrodes 19.

[0063] An air-permeable medium is likewise used for the negative collecting electrodes 17. The negative collecting electrodes 17 also consist of an electrically conductive material, for example metal, or an antistatic material, for example plastic having a surface resistance R<=10.sup.11 Ohms. For example, expanded metal, perforated sheet metal, wire cloth, welded mesh, woven wire netting and plastic mesh can be used for the negative collecting electrodes 17.

[0064] FIG. 7 shows an alternative embodiment of the collecting electrodes 17, 19 of the separation unit 170. In the case of the embodiment shown in FIG. 7, the negative collecting electrode 17 consists of a single part which is disposed between the positive collecting electrodes 19 in a snaking or meandering manner. This embodiment has the advantage that the individual negative collecting electrodes 17 do not additionally need to be electrically contacted to each other via contacts, etc.

[0065] FIGS. 8a and 8b show further embodiment of the collecting electrodes of the separation unit 170. In these embodiment variants, the collecting electrodes 17, 19 have a pleated or wavy structure respectively. This measure ensures both a reduction in the loss of pressure Delta p [Pa] of the airstream flowing through the filter medium (the separation unit 170) and an increase in the filter efficiency assuming outline conditions are otherwise unchanged. In particular, the surface area of the collecting electrodes 17, 19 can be increased for the same width and length of the filter frame 40.

[0066] In each of the embodiment of the collecting electrodes 17, 19, these can consist of a single layer. Alternatively, the positive collecting electrode 19 can also be constructed from a plurality of layers n>=1. The same applies to the negative collecting electrode 17 likewise.

[0067] The number of positive collecting electrodes 19 per filter module is >=1. The number of negative collecting electrodes 17 per filter module is likewise >=1. Spacer elements 18 can be used to increase the filter efficiency. Alternatively, these can be omitted and the positive and negative collecting electrodes 17, 19 stacked directly on top of each other. However, the spacer elements 18 result in a performance increase of the filter efficiency.

[0068] The sequence of the positive and negative collecting electrodes 17, 19 is preferably alternating as shown by way of example in FIG. 5. In addition, the first and last collecting electrode in the direction of flow can be either a positive or a negative collecting electrode in each case. This means that the first layer or electrode can be positive or negative and the last layer or electrode can likewise be positive or negative.

[0069] FIG. 9 schematically shows the electrical cabling of the electrostatic filter unit 2. The electrical power supply using extra-low voltage (<=50 V AC; <=120 V DC) or low voltage (<=1000 V AC; <=1500 V DC) is provided via contact points or low-voltage connection interfaces 26 on the primary side of the high-voltage transformer 14.

[0070] The power supply is provided via contact elements (not shown) between each individual electrostatic filter unit 2 and the vapor extractor or air cleaning device 1. The electrical contacting ideally takes place between the bearing surface of the filter frame rear side 5 and the air cleaning device 1 in the region of the suction opening. The bearing surface of the filter frame rear side 5 is that surface area of the filter frame rear side 5 which is oriented towards the top in FIG. 2. Alternatively, the electrical contact interface can be provided at any desired point of the exterior surface of the filter frame elements 4 and 5.

[0071] On the secondary side, the high-voltage line 24 with U>1 kV DC is connected via the high-voltage bus bar 13 (see FIG. 4) to the ionization elements 16 and to all positive collecting electrodes 19. The return line 23 of the secondary side is connected to all counter electrodes 15 and to the negative collecting electrode/electrodes 17. The filter frame front side 4, the filter frame rear side 5 and filter layer for prefiltering 8 are likewise connected to the return line 23 and are on the same electrical potential.

[0072] FIG. 10 shows the filter efficiency of an expanded metal filter and an embodiment of the electrostatic filter unit according to the invention 2 for the particle size range 0.3<=D.sub.hyd<=3 μm and an average flow speed c<1 m/s. It can be seen from the diagram that the electrostatic filter unit 2 according to the invention has a significantly better filter efficiency than the conventional expanded metal filter of a vapor extractor.

[0073] The present invention has a range of advantages.

[0074] The completely closed-off electrically conductive or antistatic covering with a preferred surface resistance R<=10.sup.11 Ohms, which provides the electrical screening, protects the user/consumer and the surrounding area thereof from electrical risk. By virtue of this structural design, all individual parts under high voltage are completely encapsulated by conductive or antistatic elements. Electrostatic charging of the outermost individual parts which the consumer could come into direct contact with, in particular filter frame and intervention protection, is prevented.

[0075] By virtue of the present invention having at least one protection element, electrostatic filter mechanisms can be used without presenting any danger to the user. It is thereby possible to achieve significantly better filter efficiency for liquid and solid particles having a hydraulic diameter D.sub.hyd<100 μm in comparison with the conventional grease filters in extractor hoods, particularly for low flow speeds c<2 m/s. The improved filter efficiency is achieved in particular in the embodiment of the electrostatic filter unit in which the porous collecting electrodes are used and therefore the existing mechanical separation mechanisms based on diffusion, blocking and inertia effects are supplemented by the electrostatic filter mechanisms. As a result of the significantly improved filter efficiency, particularly in the case of low flow speeds c<2 m/s, those elements of the vapor extractor which are situated behind said filter (fan, housing, odor filter) remain free from oil and dirt accumulations. Particularly in the case of recirculating vapor extractors which have an odor filter (active carbon or zeolite filter) behind the grease filter in the direction of flow, the service life (lifetime) of these recirculating filters is preserved or extended thereby, since they are not contaminated by the finest particles and therefore clogged in this case. Such an electrostatic filter cartridge has a significantly reduced loss of pressure Delta p for the same filter efficiency, in comparison with the conventional grease filter of a vapor extractor,

[0076] By virtue of a protection element being provided according to the invention, for example in the form of an insulation housing part, the high-voltage carrier can be implemented in the electrostatic filter unit without this presenting a danger to the user. Since the electrostatic filter unit can also be supplied with electrical energy from the air cleaning device via contacts, using extra-low voltage (<=50 V AC; <=120 V DC) or low voltage (<=1000 V AC; <=1500 V DC), the electrical risk to the user/consumer is further reduced.

[0077] Finally, the preferred use of air-permeable “porous” collecting electrodes instead of plate packets (a plate packet corresponds to the structure of conventional electrostatic filters used for separation) reduces the complexity and cost factor of the overall system because fewer individual parts are employed. The use of an air-permeable (porous) insulating collecting electrode results in a finely meshed electrostatic field with high electrical field strength. It allows a high separation performance in a very limited structural space in comparison with conventional plate-type electrostatic filters based on the Penney principle. As a result of the present invention, this high electrical field strength can be used without any risk to the user.

[0078] Furthermore, the use of air-permeable collecting electrodes instead of conventional electrostatic filters with plate separation, the latter having only limited storage capacity due to their structural format, results in the availability of more storage capacity. In conventional electrostatic filters with plate separation, filtered/separated particles are collected on the surface of the non-air-permeable separation plate. In the case of larger accumulations of particles, the retention capability of the surface is exhausted. The filtered/separated particles start to become detached. These are then swept away again, for example by the airstream. As a result of using air-permeable/porous collecting electrodes, holding or storing structures are produced. Any detachment of previously separated particles is greatly reduced.

[0079] Finally, by virtue of the preferred provision of an electrically insulating coating for the positive collecting electrodes, the electrodes can be placed directly on top of each other without breaking down the electrical field as a result of electrical creepage currents and spark discharges between positive and negative collecting electrodes. The electrostatic filter unit therefore has better resistance to creepage.

LIST OF REFERENCE CHARACTERS

[0080] 1 Air cleaning device [0081] 2 Electrostatic filter unit [0082] 3 Air outlet connection piece of air cleaning device [0083] 40 Filter frame [0084] 4 Filter frame front side [0085] 5 Filter frame rear side [0086] 60 Protection element [0087] 6 Protection layer [0088] 7 Spacer element for intervention protection [0089] 8 Filter layer for prefiltering [0090] 9 Inner frame [0091] 100 Ionization unit [0092] 10 Insulation housing part [0093] 11 Insulation housing part incl. mounting frame [0094] 12 Spacer [0095] 13 High-voltage bus bar [0096] 14 High-voltage transformer [0097] 15 Counter electrode [0098] 16 Ionization element/emission electrode [0099] 170 Separation unit [0100] 17 Negative collecting electrodes [0101] 18 Separation unit spacer element [0102] 19 Positive collecting electrode [0103] 20 Contact of the positive collecting electrodes [0104] 23 Return line of secondary side/connection interface of negative collecting electrode [0105] 24 High-voltage connection interface/high-voltage line of secondary side [0106] 26 Low-voltage connection interface [0107] D.sub.hyd=hydraulic diameter