Electrostatic Filter Media for Breathable Contaminant Blocking
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Solution Overview
Problem
Current mask filters face challenges in effectively filtering out both liquid and airborne contaminants, particularly in medical environments, where they need to prevent the transmission of respiratory droplets and biological agents like bacteria and viruses, while maintaining breathability and durability.
Innovation Solution
The development of nonwoven filtration media comprising bicomponent fibers, microfibrillated cellulose fibers, and glass fibers, which form a gradient structure to enhance filtration efficiency and durability, and the integration of electrostatically charged filter media and fine fiber layers to improve particle capture without significant pressure drop or loss of flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fibers are used to enhance filtration efficiency, then filtration efficiency is improved, but durability and flexibility deteriorate due to glass fiber brittleness
Solution Approach 1:
The patent removes glass fibers from the filter media composition entirely, extracting the problematic component that causes brittleness while seeking alternative materials that can provide filtration efficiency without compromising durability and flexibility
Solution Approach 2:
The patent uses composite materials consisting of polymeric fibers combined with electrostatically charged materials to achieve the desired filtration performance. This composite approach allows the filter media to maintain flexibility and durability while achieving high filtration efficiency through electrostatic mechanisms rather than relying on glass fibers
2Reliability
If fine fiber layers are added to improve particle capture, then filtration efficiency is improved, but pressure drop increases
Solution Approach 1:
The patent replaces mechanical filtration mechanisms with electrostatic mechanisms. By using electrostatically charged materials, the filter captures particles through electrostatic attraction rather than relying solely on physical blocking by fine fibers, thereby achieving high particle capture efficiency without significantly increasing pressure drop
Solution Approach 2:
The patent changes the fundamental parameter of particle capture from mechanical obstruction to electrostatic attraction. This parameter change allows the filter to achieve high efficiency at lower pressure drops by utilizing electric field interactions between charged filter materials and charged or polarizable particles
3Reliability
If filter media density is increased to block contaminants, then filtration efficiency is improved, but breathability deteriorates
Solution Approach 1:
The patent changes the mechanism of contaminant blocking from physical density-based obstruction to electrostatic field-based attraction. This allows the filter media to maintain a more open structure for breathability while achieving effective contaminant blocking through electrostatic forces that do not require high material density
Solution Approach 2:
The use of composite materials with electrostatically charged components enables the filter to achieve high contaminant blocking efficiency without requiring high density. The electrostatically charged materials provide the blocking mechanism, allowing the overall structure to remain porous and breathable
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 proposed filter media achieves high filtration efficiency, comparable to or exceeding that of glass-containing filters, while being glass-free and maintaining low pressure drop and flexibility, effectively protecting against both liquid and airborne contaminants.
Implementation Method 1
integration of electrostatically charged filter media and fine fiber layers to improve particle capture
Implementation Method 2
nonwoven filtration media comprising bicomponent fibers, microfibrillated cellulose fibers, and glass fibers, which form a gradient structure to enhance filtration efficiency
Data Source
AI summary
This disclosure describes filter media and mask filters and face mask systems including those filter media. In one aspect, the filter media includes a fibrous media including multi-component binder fibers, glass fibers, and microfibrillated cellulose fibers. In some aspects, the fibrous media further includes PET fibers. In another aspect, the filter media includes an electrostatically charged filter media, a fine fiber layer, and a scrim. In yet another aspect, the filter media includes two fine fiber layers, and two scrims. In additional aspects, the filter media includes bicomponent fibers, polyethylene terephthalate fibers, and microfibrillated cellulose fibers. In a further aspect, the filter media includes a support layer, a continuous fine fiber layer, and an efficiency layer. Combinations and composites of the filter media are also contemplated.