Deodorizing Filter Medium With Thermal-Bonded Long Fiber Laminate
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Solution Overview
Problem
Existing filtering media for air conditioning and automotive filters face challenges in achieving high deodorizing capability, adhesion, rigidity, and low pressure loss while maintaining dust-holding capacity, due to weak adhesive strength and insufficient rigidity.
Innovation Solution
A laminated filtering medium structure is developed, featuring an adsorbing layer sandwiched between base material layers, where at least one layer is a laminate sheet of needle-punched nonwoven fabric made from thermal-bonding-based long fibers and polyolefin-based fibers, with the adsorbing layer thermally bonded to the nonwoven fabric, enhancing adhesion and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If granular or fibrous adsorbents and adhesives are used to provide deodorizing capability, then deodorizing capability is improved, but adhesive strength becomes weak causing dropping of adsorbent and lowering of rigidity
Solution Approach 1:
The patent changes the fiber length parameter from conventional short fibers to long fibers (50-200 mm) in the base material nonwoven fabric. This parameter change enables the long fibers to mechanically interlock with and hold the adsorbent particles, providing both deodorizing capability and sufficient adhesive strength without requiring excessive adhesive coating that would block adsorbent pores.
Solution Approach 2:
The patent creates a composite structure combining a base material nonwoven fabric (made of long fibers) with an adsorbing layer containing adsorbent particles and adhesive. This composite material design allows the long fibers to provide structural support and mechanical adhesion while the adsorbent provides deodorizing function, resolving the contradiction between adhesive strength and deodorizing capability.
2Strength
If mixing ratio of adhesive is increased to improve adhesion, then adhesive strength is improved, but deodorizing capability decreases due to coating on adsorbent surface or pressure loss increases
Solution Approach 1:
The patent optimizes the adhesive mixing ratio to be 1-20 parts by weight per 100 parts of adsorbent, and controls adhesive coating amount to 1-50 g/m². This parameter optimization ensures sufficient adhesion while preventing excessive coating that would block adsorbent pores and reduce deodorizing capability.
Solution Approach 2:
The long fiber nonwoven fabric acts as an intermediary between the adsorbent particles and the adhesive. The fibers provide mechanical interlocking and structural support, reducing the reliance on adhesive coating for adhesion. This intermediary role allows minimal adhesive usage while maintaining both adhesion and deodorizing capability.
3Strength
If fluff of needle-punched nonwoven fabric enters in adsorbing layer to increase adhesive strength, then adhesive strength is improved, but appearance grade deteriorates and rigidity becomes insufficient
Solution Approach 1:
The patent specifies fiber length of 50-200 mm and fiber diameter of 10-100 μm for the base material nonwoven fabric. These parameter ranges ensure the fibers are long enough to provide mechanical adhesion but not so long or bulky as to create visible fluff on the surface, maintaining appearance grade while providing sufficient rigidity and adhesion.
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 a filtering medium with improved adhesion, rigidity, low pressure loss, and high dust-holding capacity, effectively addressing the limitations of previous technologies.
Implementation Method 1
the adsorbing layer and the nonwoven fabric made of thermal-bonding-based long fibers of the laminate sheet are laminated so as to be adjacent to each other and thermally bonded to each other
Data Source
AI summary
It is provided that a filtering medium for deodorizing filter which can sufficiently exhibit deodorizing capability and are excellent in pressure loss and dust-holding capacity while improving adhesion and rigidity. A filtering medium for deodorizing filter having a laminated structure formed by sandwiching an adsorbing layer containing an adsorbent and an adhesive between base material layers, wherein at least one layer of the base material layers is a laminate sheet obtained by integrally laminating a nonwoven fabric made of thermal-bonding-based long fibers and a needle-punched electret nonwoven fabric by needle punching; and the adsorbing layer and the nonwoven fabric made of thermal-bonding-based long fibers of the laminate sheet are laminated so as to be adjacent to each other and thermally bonded to each other.