Composite Filter Media for Sustained Submicron Capture

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Solution Overview

Problem

Existing filtration systems struggle to efficiently capture submicron particles, such as viruses, while maintaining longevity, dust holding capacity, and airflow, due to issues with electrostatic charge decay and non-uniform nanoparticle distribution.

Innovation Solution

A filtration media with electrostatically charged fibers and dispersed nanoparticles throughout the substrate, enhancing electrostatic capture and maintaining efficiency over time, using methods like triboelectric charging and needling to ensure uniform nanoparticle distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrostatic filters are used to capture submicron particles, then filtration efficiency is improved, but the electrostatic charge decays over time reducing longevity

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidfilter longevity

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies parameter changes by modifying the physical state and distribution of nanoparticles within the filter media. By controlling nanoparticle size, concentration, and spatial distribution throughout the substrate, the patent achieves sustained electrostatic charging without rapid decay. The nanoparticles maintain triboelectric charge over time, resolving the contradiction between initial filtration efficiency and long-term charge stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining traditional fibrous filter media with dispersed nanoparticles. This composite structure integrates the mechanical filtration capability of fibers with the electrostatic capture ability of nanoparticles, creating a hybrid system that maintains both high submicron particle capture efficiency and extended operational longevity through stable triboelectric charging.

Inventive Principle:

Principle #40Composite materials

2Reliability

If nanoparticles are added to enhance submicron particle capture, then filtration efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesubmicron particle capture efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the nanoparticle dispersion process with existing filter media manufacturing operations. By integrating nanoparticle incorporation into conventional substrate production methods, the patent achieves uniform nanoparticle distribution throughout the filter media without requiring separate, complex manufacturing steps. This combining approach maintains submicron particle capture efficiency while minimizing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If surface filters with submicron pore size are used, then particle capturing efficiency is improved, but pressure drop increases and dust loading capacity decreases

Engineering Contradiction:

Improveparticle capturing efficiencyVSAvoidpressure drop

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent replaces mechanical filtration (relying on physical pore blockage) with electrostatic filtration mechanisms. Instead of depending solely on submicron pores to mechanically trap particles, the patent uses electrostatically charged nanoparticles to attract and capture submicron particles through electrostatic forces. This substitution reduces the reliance on tight pore structures, thereby lowering pressure drop while maintaining high particle capture efficiency and increasing dust loading capacity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides high and sustained filtration efficiency for submicron particles, increased dust holding capacity, and reduced pressure drop, ensuring consistent performance throughout the filter's lifetime.

Implementation Method 1

at least one of the fibers or the nanoparticles is electrostatically charged

Methodology Applied

Scientific EffectElectrostatic charge: Electrostatics

Implementation Method 2

using methods like triboelectric charging

Methodology Applied

Scientific EffectTriboelectric charging: Triboelectric Effect

Implementation Method 3

enhancing electrostatic capture and maintaining efficiency over time

Methodology Applied

Scientific EffectElectrostatic capture: Electrostatic Induction

Data Source

PatentUS12491458B2Filters with mechanical and electrostatic filtering capabilities

Publication Date: 2025.12.09 LMS TECHNOLOGIES INC

AI summary

Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that capture submicron particles with both electrostatic forces and the utilization of nanoparticles within the filter media. A filtration media includes a substrate comprising fibers and nanoparticles disposed within the substrate. At least one of the fibers or the nanoparticles are electrostatically charged. The electrostatic charge effectively captures submicron particles during at least the initial use of the filter. The nanoparticles ensure that the efficiency of the filter remains high even after the electrostatic charge starts to decay over time. In addition, the bond between the fibers and the nanoparticles may be enhanced by the electrostatic charge, which allows the nanoparticles to be dispersed in depth throughout the filter media.