Composite Filter Media Nanofiber Adhesion
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Solution Overview
Problem
Existing composite nonwoven filter media with nanofiber layers are vulnerable to mechanical stress, prone to shedding, and have low filtration efficiency, allowing dust to penetrate and causing turbine blade fouling in gas turbines, leading to high pressure drops and frequent downtime.
Innovation Solution
A composite filter media structure featuring a spunbond nonwoven synthetic fabric base substrate with a nanofiber layer deposited on one side, using bicomponent fibers and an electro-blown spinning process to create a durable three-dimensional filtration layer with enhanced mechanical adhesion and higher basis weight, increasing filtration efficiency and reducing pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lightweight nanofiber layer is deposited on a base substrate to increase filtration efficiency, then the initial filtration efficiency improves, but the mechanical strength and durability deteriorate due to weak adhesion and vulnerability to mechanical stress
Solution Approach 1:
The base substrate is pre-treated with corona discharge or plasma treatment before nanofiber deposition to enhance surface polarity and adhesion. This preliminary action creates stronger bonding sites on the base substrate, preventing nanofiber shedding during high mechanical stress applications while maintaining the lightweight structure and high filtration efficiency.
Solution Approach 2:
The patent uses a composite structure combining a spunbond nonwoven base substrate with an electrospun nanofiber layer. The base substrate provides mechanical strength while the nanofiber layer provides high filtration efficiency. The composite achieves both durability and high performance by integrating materials with complementary properties.
2Strength
If the nanofiber layer basis weight is increased to improve durability and reduce shedding, then the mechanical strength improves, but the pressure drop increases
Solution Approach 1:
The nanofiber layer is applied selectively on one or both sides of the base substrate rather than uniformly throughout. This localized application provides enhanced durability and shedding resistance at the critical filtration surface while maintaining low pressure drop by not adding excessive weight throughout the entire filter structure.
Solution Approach 2:
The patent optimizes the nanofiber layer basis weight to a specific range (0.1-5.0 g/m2) to achieve the right balance between durability and pressure drop. This parameter optimization ensures sufficient mechanical strength and adhesion while minimizing the impact on air flow and pressure drop.
3Ease of manufacture
If a conventional wet-laid paper making process is used to produce the base substrate, then the manufacturing cost is reduced, but the mechanical stress resistance and deformation resistance deteriorate
Solution Approach 1:
The patent replaces the conventional wet-laid paper making process with a spunbond nonwoven manufacturing process. This substitution creates a base substrate with superior mechanical properties, including higher tensile strength and resistance to deformation under dust loading, while still maintaining cost-effective manufacturing through continuous production methods.
4Productivity
If the filter media operates for extended periods to reduce downtime, then productivity improves, but dust accumulation causes pressure drop increase and blade fouling
Solution Approach 1:
The base substrate is pre-treated with corona discharge or plasma treatment before nanofiber deposition to enhance surface polarity and adhesion. This preliminary action creates stronger bonding sites on the base substrate, preventing nanofiber shedding during high mechanical stress applications while maintaining the lightweight structure and high filtration efficiency.
Solution Approach 2:
The patent uses a composite structure combining a spunbond nonwoven base substrate with an electrospun nanofiber layer. The base substrate provides mechanical strength while the nanofiber layer provides high filtration efficiency. The composite achieves both durability and high performance by integrating materials with complementary properties.
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 filter media achieves a 20% increase in filtration efficiency for 0.4 μm particles with a 30% lower pressure drop, improved durability, and reduced dust penetration, enabling longer operational periods and reduced turbine downtime.
Implementation Method 1
an electro-spun technology to deposit a lightweight nanofiber coating on one or both sides of the filter media substrate
Implementation Method 2
The composite filter media achieves a 20% increase in filtration efficiency for 0.4 μm particles
Data Source
AI summary
A composite filter media structure includes, in an exemplary embodiment, a base substrate that includes a nonwoven synthetic fabric formed from a plurality of fibers with a spunbond process. The base substrate has a minimum filtration efficiency of about 50%, measured in accordance with ASHRAE 52.2-1999 test procedure A nanofiber layer is deposited on one side of the base substrate. The composite filter media structure has a minimum filtration efficiency of about 75%, measured in accordance with ASHRAE 52.2-1999 test procedure.