Bicomponent Spunbond and Meltblown Filter Medium for Low Pressure Loss
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Solution Overview
Problem
Existing filter media face challenges with high pressure loss, insufficient fraction separation, and low dust storage capacity, particularly when filtering biogenic particles like pollen, which are greater than or equal to 5 µm.
Innovation Solution
A two-layer filter medium with a spunbond carrier layer made of endless bicomponent fibers and a meltblown microfiber layer, featuring high porosity and low basis weight, which achieves efficient particle separation with low pressure loss and high dust storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine structure layer with nanometer-range fibers is used, then fraction separation capacity is improved, but pressure loss increases and dust storage capacity decreases
Solution Approach 1:
The patent changes the fiber diameter parameter from nanometer range (prior art) to micrometer range (1-20 μm, preferably 3-15 μm). This parameter change maintains fraction separation capacity while significantly reducing pressure loss and increasing dust storage capacity, as the coarser micrometer fibers create larger pores that reduce flow resistance.
Solution Approach 2:
The patent employs a highly porous microfiber layer with porosity of at least 70% (preferably at least 80%). This porous structure allows efficient particle separation through mechanical filtration while maintaining low pressure loss due to the large pore sizes, and provides high dust storage capacity through the three-dimensional pore network.
2Manufacturing precision
If a fine structure layer with nanometer-range fibers is used, then fraction separation capacity is improved, but dust storage capacity decreases
Solution Approach 1:
The patent changes the fiber diameter parameter from nanometer range to micrometer range (1-20 μm), which creates larger inter-fiber pores. This parameter change enables the layer to store more dust particles (higher dust storage capacity) while still achieving effective fraction separation, as the pore sizes are optimized for particle capture.
Solution Approach 2:
The patent uses a microfiber layer with high porosity (at least 70%, preferably at least 80%) constructed from micrometer-range fibers. The porous structure provides extensive surface area and three-dimensional pore volume for dust accumulation, enabling high dust storage capacity while maintaining separation efficiency.
3Loss of energy
If the carrier layer thickness is increased to reduce pressure loss, then pressure loss decreases, but the filter medium complexity increases
Solution Approach 1:
The patent optimizes the carrier layer thickness parameter to a specific range (0.6-2.0 mm, preferably 0.8-1.5 mm). This parameter optimization achieves low pressure loss while avoiding excessive thickness that would increase complexity and material usage. The thickness is sufficient to provide structural support and dust storage without creating unnecessary complexity.
Solution Approach 2:
The patent applies different properties to different layers: the carrier layer provides mechanical strength and structural support with optimized thickness, while the microfiber layer provides filtration function with high porosity and low basis weight. This local differentiation of properties achieves low pressure loss without requiring the entire filter medium to be uniformly thick or complex.
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 filter medium effectively separates biogenic particles and fine dust with high fractionation efficiency and low pressure loss, suitable for use in car interior filters, while maintaining a stable structure under varying pressures.
Implementation Method 1
The meltblown layer surprisingly produces excellent mechanical particle separation, in particular excellent separation of biogenic particles
Implementation Method 2
Polypropylene can be particularly well charged with long-term electrostatic charge
Data Source
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Figure 2a
AI summary
A filter medium comprising a carrier layer (1) and a microfiber layer (2) applied thereon is characterized in that, with respect to the aim of providing a filter medium which has a relatively low pressure drop, and at the same time a good fraction separation rate and excellent dust storage capacity, the carrier layer (1) has first fibers, which are designed as endless bicomponent fibers and spunbonded fibers, and the microfiber layer (2) has second fibers, which are designed as endless melt-blown fibers.