Adhesive Alloy Filter Media Bonding Without Pore Blocking

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Solution Overview

Problem

Conventional filter media layers bonded with hot melt laminates suffer from poor surface finish and reduced filtration efficiency due to penetration into and blocking of pores.

Innovation Solution

Adhesive alloys comprising a thermally activated adhesive and a polymer with different melting temperatures are melt blown onto filter media layers, thermally activated to bond them, and cooled to form a non-woven adhesive layer that minimally impacts porosity and filtration efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hot melt laminates are used to bond filter media layers, then bonding between layers is achieved, but surface finish deteriorates and filtration efficiency is reduced due to pore penetration and blocking

Engineering Contradiction:

Improvebonding strengthVSAvoidfiltration efficiency reduction

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The adhesive alloy is formulated as a porous material that can be melt-blown onto the filter media surface. The porous structure allows the adhesive to bond layers together while maintaining the porosity needed for filtration, preventing the pore blocking issue caused by conventional hot melt laminates.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention changes the physical parameters of the adhesive by creating an alloy with a eutectic composition that has a lower melting point than its individual components. This allows the adhesive to be applied at lower temperatures that do not damage the filter media or block pores, while still achieving effective bonding.

Inventive Principle:

Principle #35Parameter changes

2Strength

If hot melt laminates are used to bond filter media layers, then bonding between layers is achieved, but surface finish deteriorates

Engineering Contradiction:

Improvebonding strengthVSAvoidsurface finish

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The porous structure of the adhesive alloy allows it to conform to the filter media surface without creating a smooth, blocking layer. The porous nature maintains surface texture and prevents the poor surface finish associated with conventional hot melt laminates.

Inventive Principle:

Principle #31Porous materials

3Strength

If conventional adhesives are used to bond filter media layers, then bonding is achieved, but material usage increases and cost control is reduced

Engineering Contradiction:

Improvebonding strengthVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The invention extracts only the essential bonding function from conventional adhesives by using a thin layer of adhesive alloy applied through melt-blown technology. This eliminates the need for excessive adhesive material while maintaining effective bonding between layers.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

By changing the composition to a eutectic adhesive alloy with lowered melting point, the adhesive can be applied more efficiently with less material. The phase transition properties enable effective bonding at lower temperatures and with reduced material quantity compared to conventional adhesives.

Inventive Principle:

Principle #35Parameter changes

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 adhesive alloys provide effective bonding between filter media layers with minimal impact on flow rate and filtration performance, eliminating the need for hot melt glues and reducing material usage while offering cost control.

Implementation Method 1

heated to a temperature greater than a softening temperature of the adhesive alloy but lower than a melting temperature of the adhesive alloy

Methodology Applied

Scientific EffectSoftening: Melting

Implementation Method 2

The adhesive alloy layer is cooled to a temperature below the softening temperature of the adhesive alloy causing the adhesive alloy layer to harden and bond

Methodology Applied

Scientific EffectHardening: Freezing

Implementation Method 3

The adhesive alloy is melt blown onto a surface of a first filter media layer to form a non-woven adhesive alloy layer

Methodology Applied

Scientific EffectMelt blowing: Deposition (physical)

Data Source

PatentUS12427457B2Adhesive alloys and filter medias including such adhesive alloys

Publication Date: 2025.09.30 ATMUS FILTRATION IP INC

AI summary

Embodiments described herein relate generally to adhesive alloys and their use in filter media, and in particular to adhesive alloys that can be melt blown onto a filter media layer, and which are thermally activated to bond the filter media layer to another filter media layer. An adhesive alloy is provided. A thermally activated adhesive has a first melting temperature. A polymer has a second melting temperature greater than the first melting temperature. A ratio of the thermally activated adhesive in the adhesive alloy is in a range of 5 wt % to 70 wt %.