Bicomponent Spunbond Filter Medium With Lower Basis Weight
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Solution Overview
Problem
Existing air conditioning filters with carded nonwoven pre-filter layers require high basis weights to meet filtration standards, leading to increased material usage and costs, while alternative materials are less accessible and more expensive.
Innovation Solution
Incorporating a bicomponent spunbond layer between a carrier and melt-blown layer in the filter medium, which reduces basis weight and material usage without compromising filtration efficiency or dust holding capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a carded nonwoven pre-filter layer with high basis weight is used, then filtration efficiency and dust holding capacity are improved, but material usage and costs increase
Solution Approach 1:
The patent changes the basis weight parameter of the pre-filter layer from conventional high values (40 g/m²) to lower values (10-30 g/m²) by using bicomponent spunbond technology, achieving comparable filtration efficiency through optimized fiber composition rather than increased material quantity
Solution Approach 2:
The patent employs bicomponent fibers comprising two different polymers with distinct properties (one component for filtration efficiency, another for dust holding capacity) to create a composite material that achieves superior performance at lower basis weight compared to conventional monocomponent carded nonwoven materials
2Reliability
If a carded nonwoven pre-filter layer with high basis weight is used, then dust holding capacity is improved, but material usage and costs increase
Solution Approach 1:
The patent optimizes the basis weight parameter to lower values (10-30 g/m²) while maintaining dust holding capacity through the use of bicomponent spunbond technology, where the specific polymer composition and fiber morphology compensate for reduced material quantity
Solution Approach 2:
The bicomponent fiber composite combines two polymers with complementary properties, where one component provides dust capture capability and the other provides structural support, achieving high dust holding capacity at lower overall material usage
3Reliability
If conventional filter materials are used, then filtration performance is achieved, but material costs and environmental impact increase
Solution Approach 1:
The patent reduces the basis weight parameter to lower values, which directly decreases the total material consumption and associated environmental impact while maintaining filtration performance through optimized bicomponent fiber technology
Solution Approach 2:
The patent employs readily available, lower-cost polymer materials in a bicomponent configuration that provide effective filtration at reduced material quantities, making the filter more economically viable and environmentally friendly compared to conventional high-basis-weight filters
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 provides comparable filtration efficiency and dust holding capacity at a lower basis weight, reducing material costs and improving production efficiency with longer roll lengths and reduced environmental impact.
Implementation Method 1
a melt-blown layer; wherein the melt-blown layer is disposed between the carrier layer and the spunbond layer
Implementation Method 2
the spunbond layer comprises bicomponent fibers
Data Source
AI summary
A filter medium is provided 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 fibers. 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. The inclusion of a low density bicomponent spunbond layer as a pre-filter layer in the filter medium provides a lower basis weight filter medium with a comparable or improved filtration efficiency to a filter medium comprising a carded nonwoven pre-filter layer, while reducing the amount of materials used.