Filter material for air filter and production method therefor
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Solution Overview
Problem
Existing air filter materials face challenges in achieving high particle collection performance while maintaining low pressure loss, particularly due to limitations in the formation of a mesh-like network of polyvinyl alcohol and the presence of additional binder resins that hinder network formation.
Innovation Solution
A method involving a polyvinyl alcohol aqueous solution without additional binder resins, applied to a support with fluid permeability, is dried at 140° C or higher to form a mesh-like network of nanofibers, optimizing particle collection performance and pressure loss through controlled adhesion and evaporation rates, with a cationic surfactant optionally included to enhance these properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polyvinyl alcohol aqueous solution is applied to form a mesh-like network, then particle collection performance is improved, but production time increases due to slow drying requirements
Solution Approach 1:
The patent changes the drying temperature parameter from conventional low temperatures to 140°C or higher, which dramatically accelerates the evaporation rate of the polyvinyl alcohol aqueous solution. This parameter change enables the formation of a reliable mesh-like network structure within a short time period, resolving the contradiction between achieving high particle collection performance and maintaining short production time.
Solution Approach 2:
The patent utilizes the phase transition of water from liquid to vapor through rapid evaporation at high temperature (140°C or higher). This phase transition mechanism allows the aqueous solution to quickly form a solid mesh-like network structure after application, significantly reducing the drying time while ensuring the formation of the desired network structure for high particle collection performance.
2Strength
If additional binder resins are mixed with polyvinyl alcohol, then adhesion is improved, but mesh-like network formation is hindered
Solution Approach 1:
The patent extracts and removes additional binder resins from the polyvinyl alcohol aqueous solution, using only pure polyvinyl alcohol. This extraction eliminates the interference of other resins that would prevent the formation of a proper mesh-like network structure. The patent achieves adequate adhesion through the pure polyvinyl alcohol network without the need for additional binder resins, thus resolving the contradiction between adhesion and mesh-like network formation.
Solution Approach 2:
The patent uses a homogeneous polyvinyl alcohol aqueous solution without mixed binder resins, ensuring uniform distribution and consistent network formation throughout the filter material. This homogeneity allows the polyvinyl alcohol to form a reliable mesh-like network structure uniformly across the material, achieving both adequate adhesion and proper network formation simultaneously.
3Stability of the object's composition
If polyvinyl alcohol is used to bind glass fibers, then dispersibility is improved, but network structure formation is prevented by other mixed binder resins
Solution Approach 1:
The patent extracts and eliminates other mixed binder resins from the system, using only polyvinyl alcohol as the binder. This removal allows the polyvinyl alcohol to freely form a mesh-like network structure between glass fibers without interference, while still maintaining improved dispersibility of the glass fibers. The pure polyvinyl alcohol system achieves both dispersibility enhancement and network structure formation simultaneously.
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 method effectively improves particle collection performance and maintains low pressure loss by forming a reliable mesh-like network of polyvinyl alcohol nanofibers within the air filter material, enhancing its filtration efficiency and productivity.
Implementation Method 1
a drying step of drying the polyvinyl alcohol aqueous solution adhering to the support in the wet state at 140° C. or higher
Data Source
AI summary
A method for producing a filter material for an air filter according to the present disclosure includes: an adhering step of getting a polyvinyl alcohol aqueous solution adhering to a support, having fluid permeability, to bring the support into a wet state; and a drying step of drying the polyvinyl alcohol aqueous solution adhering to the support in the wet state at 140° C. or higher, in which the polyvinyl alcohol aqueous solution contains no other binder resins than polyvinyl alcohol, and the support, after the drying step, has the mesh-like network of polyvinyl alcohol, in the pore serving as a fluid permeation path, by drying the polyvinyl alcohol aqueous solution.