Air Filter Material Laminate for Dust Penetration Resistance

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Solution Overview

Problem

Conventional air filter materials for automobile engines face challenges in maintaining a well-balanced dust collection capability, dust penetration resistance, and carbon soot collection capability, often requiring expensive splittable fibers, which increases manufacturing costs and can lead to clogging issues due to excessive resin use.

Innovation Solution

A nonwoven-based air filter material is configured as a laminate of a needle punched nonwoven fabric layer as the air inlet layer and a laminated spunlace nonwoven fabric layer as the air outlet layer, with specific pore size and fiber weight ranges, eliminating the need for splittable fibers and optimizing airflow resistance and cleaning efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a dense fiber layer with fine fibers is used to improve dust collection capability, then dust collection capability is improved, but dust penetration resistance deteriorates due to vibration-induced penetration around 200 Hz

Engineering Contradiction:

Improvedust collection capabilityVSAvoiddust penetration resistance

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The filter medium is divided into two distinct layers: a dense fiber layer for dust collection and an adjacent fiber layer with higher apparent density for preventing dust penetration. This segmentation allows each layer to specialize in its function, resolving the contradiction between dust collection and penetration resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the filter medium are assigned different properties: the dense fiber layer has fine fibers (3-15 μm) for high dust collection, while the adjacent fiber layer has coarser fibers and higher apparent density (0.1-0.2 g/cm³) for vibration resistance. This local differentiation allows simultaneous optimization of both functions.

Inventive Principle:

Principle #3Local quality

2Reliability

If resin is impregnated to fix fibers and improve dust penetration resistance, then dust penetration resistance is improved, but carbon soot collection capability deteriorates due to clogging

Engineering Contradiction:

Improvedust penetration resistanceVSAvoidcarbon soot collection capability

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The apparent density of the adjacent fiber layer is increased to 0.1-0.2 g/cm³, creating a denser structure that resists dust penetration through vibration without requiring excessive resin. This parameter change allows mechanical stability while maintaining porosity for carbon soot collection.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The filter medium combines two types of fibers with different properties: fine fibers for dust collection and coarser, denser fibers for structural stability. This composite structure achieves both dust penetration resistance and carbon soot collection capability without over-reliance on resin binding.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If splittable fibers are used to achieve favorable filtering performance, then cleaning efficiency is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Instead of using expensive splittable fibers throughout, the invention applies fine fibers only in the dense fiber layer where dust collection is needed, while using常规 fibers in the adjacent layer for structural support. This localized approach maintains cleaning efficiency while reducing overall material cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The adjacent fiber layer uses conventional, cost-effective fibers with higher apparent density to provide the structural framework that prevents dust penetration. This substitutes expensive splittable fibers with cheaper alternatives in the structural layer, reducing manufacturing cost while maintaining performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 provides excellent dust penetration resistance, initial flow resistance, and cleaning efficiency against dust and carbon soot, maintaining a well-balanced performance without the use of expensive fibers, thus reducing costs and improving filter life and efficiency.

Implementation Method 1

an air filter material comprising a laminate of an air inlet layer and an air outlet layer

Methodology Applied

Scientific EffectPhysical barrier filtration: Filter (physical)

Implementation Method 2

having a mean flow pore size of 20 μm to 40 μm, a minimum pore size of 2.4 μm to 3.8 μm, and a maximum pore size of 80 μm or less

Methodology Applied

Scientific EffectPore size control: Porosity

Data Source

PatentUS7968176B2Air filter material

Publication Date: 2011.06.28 DYNIC CORPORATION

AI summary

An air filter material includes a laminate of an air inlet layer and an air outlet layer, and has a mean flow pore size of 20 μm to 40 μm, a minimum pore size of 2.4 μm to 3.8 μm, and a maximum pore size of 80 μm or less. The air inlet layer is a needle punched nonwoven fabric layer having an areal fiber weight of 55 g/m2 to 100 g/m2. The air outlet layer is a laminated spunlace nonwoven fabric made by laminating at least two or more spunlace nonwoven fabric layers having an areal fiber weight of 20 g/m2 to 60 g/m2, a mean flow pore size of 50 μm to 90 μm, a minimum pore size of 3.0 μm to 10.0 μm, and a maximum pore size of 180 μm or less.