Bicomponent Spunbond Filter Medium for Lower-Basis-Weight Dust Loading
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Solution Overview
Problem
Existing air conditioning filters with carded nonwoven pre-filter layers require high basis weights for high dust holding capacity, leading to increased material usage and costs, while offering limited filtration efficiency improvements.
Innovation Solution
Incorporating a bicomponent spunbond layer between a carrier and melt-blown layer in the filter medium, which reduces basis weight and thickness, enhancing filtration efficiency and dust holding capacity while using more readily available and cost-effective materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a carded nonwoven pre-filter layer with high basis weight is used, then dust holding capacity is improved, but material usage and production costs increase
Solution Approach 1:
The patent employs a composite pre-filter layer combining carded nonwoven material with bicomponent fibres (different melting points). This composite structure enables the filter to achieve high dust holding capacity through the synergistic effect of the carded base material and the bonding action of bicomponent fibres, while reducing the overall basis weight compared to traditional high-weight carded nonwoven filters. The bicomponent fibres melt at different temperatures to create effective particle trapping without requiring excessive material.
Solution Approach 2:
The patent changes the physical and chemical parameters of the pre-filter layer by incorporating bicomponent fibres with specific melting point differences. This parameter change allows the filter to achieve enhanced dust holding capacity through thermal bonding mechanisms rather than relying solely on increasing material quantity. The melting point differentiation enables controlled fibre bonding at specific temperatures, improving filtration performance with reduced material usage.
2Reliability
If a carded nonwoven pre-filter layer with high basis weight is used, then dust holding capacity is improved, but production costs increase
Solution Approach 1:
The composite structure using bicomponent fibres with different melting points creates a cost-effective solution by enabling thermal bonding during the forming process. This reduces the need for additional bonding steps and materials, lowering production costs while maintaining high dust holding capacity. The differential melting points allow for in-line bonding during filter manufacturing, streamlining the production process.
Solution Approach 2:
By changing the material composition to include bicomponent fibres with specific thermal properties, the patent enables a more efficient manufacturing process. The thermal bonding capability reduces production complexity and material waste, thereby lowering production costs while achieving the required dust holding capacity performance.
3Quantity of substance
If a bicomponent spunbond layer with lower basis weight is used, then material usage is reduced, but filtration efficiency may be compromised
Solution Approach 1:
The patent creates a composite pre-filter layer that combines carded nonwoven material with bicomponent fibres. This composite approach allows the lighter-weight spunbond structure to achieve adequate dust holding capacity through the synergistic bonding action of the bicomponent fibres, maintaining filtration efficiency without requiring high basis weight. The carded material provides the structural framework while bicomponent fibres enhance particle capture.
Solution Approach 2:
The bicomponent fibres are strategically distributed within the spunbond layer to provide localized bonding and particle trapping zones. This local quality enhancement allows the overall filter to maintain high filtration efficiency with reduced material usage, as the bicomponent fibres concentrate their functional effect in critical areas rather than requiring uniform high material density throughout.
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 bicomponent spunbond layer achieves comparable filtration efficiency and dust holding capacity to carded nonwoven layers with lower material usage, reducing production costs and improving production efficiency by extending roll length and minimizing downtime.
Implementation Method 1
melt-blowing a polymer onto a carrier layer to form a first composite comprising a melt-blown layer and a carrier layer
Implementation Method 2
melt-blowing a polymer onto a carrier layer to form a first composite
Data Source
Figure 1
AI summary
Described herein is a filter medium comprising a carrier layer; a melt-blown layer; and a spunbond layer. The melt-blown layer is disposed between the carrier layer and the spunbond layer. The spunbond layer comprises bicomponent fibres. The spunbond layer may have a basis weight of from about 10 g/m2 to about 40 g/m2 and may have a thickness of at least about 250 µm. Also described herein is a method of producing the filter medium and filters and apparatus comprising the filter medium.