Composite Filter Medium with Surface Beads for Low Pressure Loss
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Solution Overview
Problem
Conventional filter media using ultrafine fibers face challenges in achieving high dust collection efficiency, low pressure loss, and long lifespan, with existing solutions either increasing pressure loss or complicating manufacturing processes.
Innovation Solution
A composite structure comprising ultrafine fibers with a fiber diameter of less than 500 nm and beads with a diameter of 5 μm or more, where the beads are distributed at a density of at least 500/mm² on the outermost surface, improving dust collection efficiency and reducing pressure loss while maintaining a reasonable manufacturing process and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrafine fibers are used to achieve high dust collection efficiency, then collection efficiency is improved, but pressure loss increases due to dense fiber matrix
Solution Approach 1:
The patent combines ultrafine fibers with beads to create a composite filter medium. The ultrafine fibers provide high dust collection efficiency while the beads create void spaces that reduce pressure loss. This composite structure allows the filter to achieve both high collection efficiency and low pressure loss simultaneously.
Solution Approach 2:
The patent applies local quality by having different components (ultrafine fibers and beads) occupy different spatial regions with specific functions. The ultrafine fibers are distributed throughout the matrix for dust collection, while beads are strategically placed to create void spaces for fluid flow, optimizing both collection efficiency and pressure loss characteristics in different locations.
2Stress or pressure
If mixed fiber filter medium combining different manufacturing methods is used to reduce pressure loss, then pressure loss is reduced, but manufacturing apparatus becomes complicated
Solution Approach 1:
The patent merges the ultrafine fiber formation process with bead formation into a single electrostatic spinning process. Instead of using separate manufacturing methods for different fiber types, the process combines both components into one integrated manufacturing step, simplifying the apparatus and process while achieving the desired pressure loss reduction.
Solution Approach 2:
The electrostatic spinning apparatus is designed to perform multiple functions: it forms ultrafine fibers, generates beads, and creates the composite structure all in one process. This multi-functional approach eliminates the need for separate manufacturing lines and reduces overall apparatus complexity compared to combining different manufacturing methods.
3Length of moving object
If beads are made very small to maintain thin fiber diameter, then fiber diameter is reduced, but sufficient interfiber distance cannot be secured
Solution Approach 1:
The patent optimizes the bead size parameter to a specific range (0.1 to 10 μm) that simultaneously achieves thin fiber diameter and sufficient interfiber distance. This parameter optimization allows the composite structure to maintain both characteristics by carefully controlling the bead dimensions within this specific range.
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 composite structure achieves high dust collection efficiency, low pressure loss, and extended lifespan as a filter medium, with the specific distribution and size of beads optimizing the filter's performance and manufacturing efficiency.
Implementation Method 1
spinning the spinning solution in an electrostatic spinning method and obtaining a composite structure containing ultrafine fibers and beads
Data Source
AI summary
Provided are: a filter medium with high dust collection efficiency, low pressure loss, and a long lifespan; and a filter material used for the filter medium. This composite structure includes ultrafine fibers having a fiber diameter of less than 500 nm, and beads. The outermost surface of the composite structure has at least 500/mm2 of beads with a diameter of 5 μm or more. The ultrafine fibers and the beads preferably have the same component.