Embossed Filter Element for Particle Removal and Flow Rate
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Solution Overview
Problem
Existing filters, such as those described in JP 2004-500229 A, face limitations in performance regarding particle removal efficiency and flow rate characteristics, particularly when calendering is used to compress the filter member, which can compromise the filter's ability to maintain particle removal effectiveness under stress and flow conditions.
Innovation Solution
A filter design featuring a tubular filter member with an embossed surface, where the embossed portion is formed on both sides of the nonwoven fabric, providing enhanced particle removal performance and flow rate characteristics by maintaining fiber position and reducing mobility, while allowing for efficient capture of particles across a wide range of sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calendering is performed to compress the filter member, then particle removal performance is improved, but flow rate characteristics deteriorate and structural integrity is compromised
Solution Approach 1:
The filter member incorporates an embossed portion with a specific pattern (such as dots, lines, or geometric shapes) on its surface, creating localized structural features that improve particle removal performance without requiring overall compression of the entire filter member. This localized modification allows the filter to maintain better flow rate characteristics while achieving enhanced filtration effectiveness.
2Manufacturing precision
If calendering is performed to compress the filter member, then particle removal performance is improved, but reliability under stress deteriorates
Solution Approach 1:
Instead of uniformly compressing the entire filter member, the embossed portion is localized to specific areas, creating a patterned structure that enhances particle removal capability. This localized approach preserves the overall structural integrity and reliability of the filter member under stress, as the unembossed portions maintain their original strength and flexibility.
3Manufacturing precision
If calendering is performed to compress the filter member, then particle removal performance is improved, but service life deteriorates
Solution Approach 1:
The embossed portion creates a durable, patterned structure on the filter member surface that provides long-lasting particle removal performance. This localized structural modification is more sustainable than overall compression, as it maintains the filter member's integrity and prevents premature degradation, thereby extending service life while preserving filtration effectiveness.
Data Source
AI summary
A filter (1) includes a filter element (2) having a filter member (10) with a tubular shape disposed on the outer side of a porous tube (7), and the filter member (10) includes an embossed portion (21) formed on a surface of the filter member (10).