Multi-Layer Filter Media Odor Control
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Solution Overview
Problem
Current filter media struggle with odor control, pressure drop, and efficiency in removing submicron particulates, particularly in vacuum cleaners and industrial applications, where they often fail due to mold growth and high pressure drops, and require complex cleaning methods that can damage the filter.
Innovation Solution
A multi-layered HEPA filter media construction using an upstream ePTFE layer, a bi-component polyethylene/polyethylene terephthalate layer, and a base layer with activated carbon, which provides anti-microbial properties and improved odor control while maintaining low pressure drop and high filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If HEPA filter media with fine fiber layers are used to remove submicron particles, then filtration efficiency is improved, but the filter becomes difficult to clean and dust particles become trapped in the depth of the filter media
Solution Approach 1:
The filter media is divided into multiple layers with different functions: a hydrophobic layer for particle capture and a hydrophilic layer for particle release during cleaning. This segmentation allows each layer to be optimized for its specific function, solving the contradiction between high efficiency and cleanability.
Solution Approach 2:
The filter media uses porous materials with specific pore size distributions and surface properties. The hydrophobic layer has pores that capture particles while the hydrophilic layer has pores that allow easy particle release during water-based cleaning, resolving the contradiction between particle trapping efficiency and cleanability.
2Manufacturing precision
If filter media with deep particle trapping capability is used, then filtration efficiency is improved, but vacuum power is reduced and filter life is shortened
Solution Approach 1:
By segmenting the filter into capture and release layers, particles are trapped on the surface of the hydrophobic layer rather than being embedded deep in the media. This maintains vacuum power while achieving high filtration efficiency through the surface-capture mechanism.
Solution Approach 2:
The invention changes the surface energy parameters of different layers to create hydrophobic and hydrophilic regions. This parameter change allows particles to be strongly attracted to the hydrophobic layer during filtration but easily released during water-based cleaning, maintaining both efficiency and productivity.
3Ease of operation
If conventional filter cleaning methods like rapping are used, then dust dislodgement is achieved, but the filter media fails or multilayered elements delaminate
Solution Approach 1:
The invention replaces mechanical cleaning methods (rapping, vibration) with a chemical/capillary action-based cleaning method using water or water-based solutions. The hydrophilic layer attracts water which capillary forces draw through the layer, releasing particles without mechanical stress that could cause delamination or media failure.
Solution Approach 2:
Water acts as an intermediary substance that facilitates particle removal from the filter media. The hydrophilic layer's affinity for water allows water to penetrate and release particles, while the hydrophobic layer's water repellency protects the structural integrity of the media during the cleaning process.
4Object-generated harmful factors
If activated carbon is added for odor control, then odor removal is improved, but pressure drop increases
Solution Approach 1:
Activated carbon is applied locally in specific zones or layers of the filter media where odor control is most needed, rather than uniformly throughout the entire filter. This localized application provides odor control while minimizing the overall pressure drop across the filter structure.
Solution Approach 2:
The filter media uses composite materials combining activated carbon particles with the hydrophobic/hydrophilic layer structure. This composite construction allows odor control functionality to be integrated into the existing low-pressure-drop architecture, rather than adding a separate high-resistance carbon layer.
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 multi-layered filter media effectively removes submicron particles with HEPA efficiency, reduces pressure drop, and prevents mold growth, enhancing air quality and filter longevity by integrating odor control and anti-microbial treatment in a single medium.
Implementation Method 1
a base layer which can be any type of filter media that is suitable for the application, although it is believed that the base layer is best suited to be a material such as activated carbon
Implementation Method 2
A multi-layered HEPA filter media construction using an upstream ePTFE layer, a bi-component polyethylene/polyethylene terephthalate layer, and a base layer with activated carbon
Implementation Method 3
inertial separators tend to simply place a physical barrier in the path of particulate material that is then knocked from the air stream into a collection bin
Data Source
AI summary
Disclosed herein, among other things, is an improved filter media construction that comprises multiple layers for improved odor control that can be used for vacuum cleaner air filtration cartridge applications. The filter media comprises anti-microbial ePTFE HEPA filter media to prevent mold growth. The filter media may also be used for air cleaner filtration, central air filtration for home and industrial buildings (HVAC), cleanrooms, and microelectronic devices. In an embodiment, the improved filter media construction comprises at least a PTFE layer, a bi-component layer, and a base layer. In an embodiment the PTFE layer comprises ePTFE. In an embodiment, the bi-component layer comprises non-woven polyethylene/polyethylene terephthalate (PE/PET). In yet another embodiment, the base layer comprises activated carbon. Other aspects and embodiments are provided herein.