Composite Vacuum Cleaner Filter Bag for Low Pressure Loss
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Solution Overview
Problem
Existing filter bags for vacuum cleaners have insufficient dust storage capacity and excessive pressure loss when dealing with a wide range of particle sizes, as seen in prior art technologies.
Innovation Solution
A filter bag composed of at least three layers, with two layers being a non-woven fiber layer and a fleece layer connected by a welded connection, where the non-woven fiber layer consists of uncharged filaments or fibers, and the welding pattern covers no more than 5% of the filter bag's surface area, with an average of 20 welded joints per 10 cm², and includes a composite layer of different non-woven materials for enhanced dust storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrostatically charged split fibers are connected by ultrasonic weld connection with high welding coverage (at least 5% surface area with at least two spot welds per cm²), then the filter medium gains stability and production costs are reduced, but the dust storage capacity becomes insufficient
Solution Approach 1:
The filter medium is divided into multiple layers with different functions: a first nonwoven fabric layer for structural stability, a second nonwoven fabric layer for dust storage, and a third nonwoven fabric layer for filtration. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between stability and dust storage capacity.
Solution Approach 2:
The welding pattern is designed with local quality by concentrating welded joints at the edges and intersections of the filter bag rather than distributing them uniformly across the entire surface. This provides sufficient structural stability at critical locations while maintaining high dust storage capacity in the main filtration areas.
2Quantity of substance
If a filter medium with high dust storage capacity is used, then more dust can be stored, but pressure loss increases
Solution Approach 1:
The filter medium utilizes porous nonwoven fabric materials with controlled pore structures that allow dust particles to be stored within the matrix while maintaining adequate airflow. The porous structure enables high dust storage capacity without creating excessive resistance to air flow, thus minimizing pressure loss.
Solution Approach 2:
The filter bag employs a composite structure of multiple nonwoven fabric layers with different properties. The combination of layers creates a material system that simultaneously achieves high dust storage capacity and low pressure loss by optimizing the interaction between layers.
3Reliability
If the welding pattern covers a large surface area (more than 5%), then the filter medium becomes more stable, but the dust storage capacity is reduced
Solution Approach 1:
Instead of applying welding uniformly across the entire surface, the invention uses partial action by concentrating welded joints only at critical locations such as edges and intersections. This provides sufficient stability without occupying excessive surface area that would reduce dust storage capacity.
4Reliability
If needling process is used to connect fibers, then the filter medium achieves stability, but production costs increase significantly
Solution Approach 1:
The invention replaces the mechanical needling process with an ultrasonic welding system that uses vibrational energy to bond fibers. This substitution maintains the stability and strength of the filter medium while significantly reducing production costs and improving manufacturing efficiency.
Solution Approach 2:
The invention changes the bonding mechanism from mechanical interlocking (needling) to thermal-vibrational bonding (ultrasonic welding). This parameter change in the connection method achieves comparable or superior stability at lower production costs.
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 significantly increases dust storage capacity while minimizing pressure loss, achieving superior filtration performance with a more cost-effective and stable filter medium.
Implementation Method 1
at least one nonwoven fiber layer and at least one nonwoven fabric layer are connected to one another by means of a welded connection
Data Source
AI summary
The invention relates to a filter bag for a vacuum cleaner. Said filter bag is made of a composite material encompassing at least three layers. At least two layers, which are composed of a fleece layer and at least one fiber fleece layer, are connected by means of a welded joint. The invention further relates to the use of such a filter bag.