Charged Polyester Meltblown Filter Medium
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Solution Overview
Problem
Existing engine air filter media face challenges in achieving high filtration efficiency and dust holding capacity while being cost-effective and easy to produce using standard manufacturing processes.
Innovation Solution
A filter medium comprising a carrier layer and a meltblown layer made of polyester fibres, specifically polybutylene terephthalate, which is electrically charged to enhance filtration efficiency and dust holding capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nanofibre layers are used to increase filtration efficiency, then filtration efficiency is improved, but manufacturing complexity increases and cost increases
Solution Approach 1:
The patent changes the physical-chemical parameter of the filter medium by applying an electrical charge to the meltblown layer. This electrical charge enhances the filtration efficiency through electrostatic attraction of particles, allowing the use of larger fibre diameters (2-8 μm) instead of nanofibres, thereby simplifying the manufacturing process while maintaining high filtration efficiency.
2Manufacturing precision
If nanofibre layers are used to increase filtration efficiency, then filtration efficiency is improved, but production cost increases
Solution Approach 1:
The patent applies electrical charge to the meltblown layer, changing its physical-chemical properties. This allows the use of standard meltblown technology with larger, cheaper fibres instead of expensive nanofibre production processes, significantly reducing manufacturing costs while achieving high filtration efficiency through electrostatic filtration.
Solution Approach 2:
The patent uses a disposable meltblown layer with electrical charge that can be produced cost-effectively using standard manufacturing processes. The electrical charge provides enhanced filtration performance without requiring expensive, complex nanofibre production, making the filter medium more economical while maintaining high performance.
3Manufacturing precision
If electrical charge is applied to enhance filtration efficiency, then filtration efficiency and dust holding capacity are improved, but charge stability under high dust conditions must be maintained
Solution Approach 1:
The patent uses a composite structure consisting of a carrier layer and an electrically charged meltblown layer. The carrier layer provides mechanical stability and structural support, while the meltblown layer with electrical charge provides enhanced filtration efficiency. This composite structure ensures that the electrical charge remains stable and effective even under high dust conditions, as the carrier layer protects the charged meltblown layer.
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 charged filter medium demonstrates improved filtration efficiency and dust holding capacity compared to non-charged media, allowing for larger fibre diameters, cheaper manufacturing, and higher performance with the same pressure drop.
Implementation Method 1
the filter medium is electrically charged... the charged filter media of the present invention has better efficiency and dust holding capacity
Data Source
AI summary
A filter medium for engine air filters contains a support layer and a meltblown layer containing polyester fibres. The filter medium is electrically charged.