Filter material for air filter, method for manufacturing same, and air filter provided with same
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Solution Overview
Problem
Current air filter media face a challenge in achieving a high Pressure Drop Factor (PF) value, which indicates low pressure drop and high collecting efficiency, while minimizing energy consumption and operational costs.
Innovation Solution
A filter media composed of wet-laid nonwoven fabric with submicron glass fibers and a binder fiber, impregnated with a fluorine resin and surfactant, where the binder resin is limited to 50% by mass or less, ensuring uniform dispersion of glass fibers and enhanced particle capturing action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the formulation of fine fiber is increased to increase collecting efficiency, then the collecting efficiency is improved, but the pressure drop increases
Solution Approach 1:
The invention changes the chemical composition parameters of the filter media by incorporating fluorine-containing resin and silicon resin coatings on glass fibers, and using specific binder resins, to achieve high collecting efficiency without proportionally increasing pressure drop
Solution Approach 2:
The invention uses composite materials consisting of glass fibers coated with fluorine-containing resin and silicon resin, combined with specific binder resins, to create a filter media that achieves high collecting efficiency while controlling pressure drop through the synergistic effects of different materials
2Reliability
If the formulation of fine fiber is increased to increase collecting efficiency, then the collecting efficiency is improved, but the operation load and power consumption increase
Solution Approach 1:
The invention optimizes the chemical composition parameters including fluorine-containing resin content (0.1-5% by mass), silicon resin content (0.1-5% by mass), and binder resin type to achieve high collecting efficiency while minimizing the power consumption required for fan operation
Solution Approach 2:
The composite filter media structure with coated glass fibers and specific binder resins reduces the fine fiber formulation needed to achieve a given collecting efficiency, thereby reducing the operation load and power consumption of the intake fan
3Strength
If binder resin is increased to maintain strength, then the strength is improved, but the PF value decreases due to pore clogging
Solution Approach 1:
The invention changes the binder resin composition parameters by selecting specific resin types (polyester, polyamide, polyacrylic acid, or polyacrylonitrile) and controlling the binder resin content ratio (fluorine-containing resin: silicon resin: binder resin = 100: 100: 10-500) to maintain filter media strength without excessive pore clogging
Solution Approach 2:
The binder resin acts as an intermediary material that bonds the coated glass fibers together while maintaining pore structure, allowing the filter media to maintain strength with minimal binder resin content that does not clog pores excessively
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 results in a filter media with an extremely high PF value, maintaining filtration performance and strength while reducing energy consumption and operational costs.
Implementation Method 1
a method for allowing a binder, and a fluorine-based surfactant having the lowest surface tension of 20 dyne/cm or less at the time of adding into pure water at 25°C to adhere to a glass fiber constituting a filter media
Implementation Method 2
a fluorine-based surfactant having the lowest surface tension of 20 dyne/cm or less at the time of adding into pure water at 25°C
Implementation Method 3
a collecting technique of an air filter has been used to collect a dust particle having a submicron to micron unit in the air
Data Source
AI summary
The present invention is to provide a filter media for an air filter having a PF value higher than ever, and an air filter provided with the same. The filter media for an air filter according to the present invention is composed of wet-laid nonwoven fabric containing a glass fiber having an average fiber diameter of less than 1 µm, and a binder fiber, and is characterized in that the wet-laid nonwoven fabric contains a fluorine resin and a surfactant, and does not contain a resin binder or contains a binder resin in an amount of 50% by mass or less based on the fluorine resin.