Advanced Materials

High-Efficiency Ceramic Reinforced Activated Carbon Composite

North Africa | January 2023 - September 2023

advanced-mat

Client Challenge

Client Challenge

An automotive component supplier partnered with Tml Industries to improve molecular filtration performance in both car cabin air systems and domestic air purifiers. The client was seeking a new filter media with improved efficiency, longer service life and better operational durability in high temperature and humidity conditions.

Earlier solutions using standard carbon granules had several problems, including declining filtration performance due to surface wear, uneven airflow and pressure drops, and weak control of odors and VOCs in small filter spaces.

Tml’s Solution

Tml’s Solution

Tml’s R&D division proposed a ceramic-reinforced activated carbon composite, engineered for molecular-level air filtration in demanding environments. This composite was designed to increase surface area, thermal stability, and filtration capacity while maintaining low resistance to airflow.

Development highlights:

1

Material innovation

Integrated fine-pore activated carbon with ceramic micro-particles in a polymer binder

2

Thermal processing

Developed a stable sintering process to form durable, uniform filtration blocks

3

Application versatility

Designed modular inserts for both automotive HVAC and residential air purifiers

4

Trial production

A pilot run of 1,000 units tested across 3 use environments, including vehicles and indoor appliances

5

Performance benchmarking

Lab-tested to compare VOC adsorption rate, lifespan, and airflow resistance

Results

Results

This case confirmed Tml’s capability to design custom composite materials personalized for industry applications by combining performance, longevity, and manufacturability at scale.

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Achieved 40% higher VOC removal rate than conventional filters

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Maintained structural integrity up to 120°C, ideal for engine-compartment applications

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Reduced need for filter replacement by extending operational life by 2.5x

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Pressure drop maintained below 50 Pa, ensuring optimal airflow

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Product adopted in two local OEM vehicle lines and a home appliance brand within 6 months of launch

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