Embossed Vacuum Cleaner Filter Bag for High Volume Flow
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Solution Overview
Problem
Conventional filter bags for vacuum cleaners experience a significant decrease in filter performance and volume flow as they become clogged, leading to reduced effectiveness in dust particle filtration.
Innovation Solution
The filter bag is designed with embossed filter material that increases the effective filter surface area through profiling, using elevations and hemispheres, and a multi-layer structure with a pre-filter, coarse dust storage, and fine filter layers, along with optional nanofiber layers, to enhance filtration efficiency and reduce clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the filter bag is used continuously, then the dust collection capacity increases, but the filter performance and volume flow decrease due to clogging
Solution Approach 1:
The filter material is embossed with three-dimensional profiles (elevations, hemispheres, ribs) that protrude from the flat surface, transforming the filter surface from two-dimensional to three-dimensional. This increases the effective filter surface area by more than 10%, preferably by more than 20% or 30%, allowing greater dust collection capacity while maintaining adequate volume flow through the increased surface area
2Productivity
If the filter surface area is increased to maintain volume flow, then the filter bag geometry becomes larger, but the device size and complexity increase
Solution Approach 1:
Instead of increasing the planar dimensions of the filter bag, the invention embosses the existing filter material surface with three-dimensional profiles. The profiles (elevations, hemispheres, ribs) with heights of at least 1 to 2 mm, in particular more than 3 mm, create additional filter surface area within the same footprint, increasing effective surface area by more than 10%, preferably by more than 20% or 30% without increasing the overall filter bag dimensions
3Reliability
If a multi-layer filter structure is implemented to improve filtration efficiency, then the manufacturing complexity and cost increase
Solution Approach 1:
The filter material is embossed with profiles at specific locations and patterns (grid sizes between 1 cm and 3 cm) to create local variations in surface area and filtration characteristics. The profiling can be applied selectively to different regions of the filter bag, allowing optimization of filtration efficiency in areas with higher dust loading while maintaining simpler structures in other areas, thus improving filtration efficiency without uniformly increasing overall complexity
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
This design significantly improves filter performance by maintaining a high volume flow and filtration efficiency even under increased load, with a notable increase in effective filter surface area and reduced clogging, resulting in better dust separation and suction power.
Implementation Method 1
the air to be cleaned can flow into the filter bag, in order to then flow through the filter material of the filter bag and be cleaned in the process, the filter material comprising at least one layer of nonwoven fabric
Implementation Method 2
the filter material can have an increasing fiber density on the outflow side, so that even very small particles can be filtered on the outflow side
Data Source
Figure 1~2
Figure 3
AI summary
The filter is formed with two layers of fibre material [2] that are joined along the edges [3].Set into the centre is a plastic holder [4] with a centre hole for air flow. This is used to fit the unit into a vacuum cleaner. The effective area of the filter is increased by formed dome sections [6].