Filter Reinforcing Material for Deodorizing Filter Pleating
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Solution Overview
Problem
Conventional air filter media used in automobiles and households face challenges with low strength and stiffness, leading to issues such as peeling and pleat adhesion during pleating, which affects filtration performance and shape retention, especially when subjected to high processing wind speeds.
Innovation Solution
A filter reinforcing material comprising a bonding layer of thermal bonded nonwoven with thermal bondable short fibers and a reinforcing layer of high-melting fibers with a melting point difference of at least 30°C, integrated through thermal fusion bonding, which enhances stiffness and prevents peeling and pleat adhesion during pleating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing material with high strength and high stiffness is attached to the air filter medium, then strength and stiffness are improved, but peeling occurs at the time of pleating
Solution Approach 1:
The invention changes the physical and chemical parameters of the reinforcing material by using biaxial stretching to create a oriented structure with specific mechanical properties. The reinforcing material is designed with tensile strength of 20-80 N/wide and elongation at break of 10-30%, creating a balance between stiffness and flexibility that prevents peeling during pleating while maintaining structural support
Solution Approach 2:
The invention creates a composite structure by laminating the oriented nonwoven fabric (reinforcing layer) with the meltblown nonwoven (filter layer) in a specific arrangement. This composite structure combines the high strength and stiffness of the oriented nonwoven with the filtration properties of the meltblown nonwoven, achieving both structural integrity and functional performance without peeling
2Productivity
If the filter medium is pleated to increase filtration area, then filtration capacity is improved, but pleat adhesion occurs during heat treatment
Solution Approach 1:
The invention changes the thermal parameters by selecting materials with appropriate melting points. The oriented nonwoven fabric uses polypropylene with melting point 160-170°C while the meltblown nonwoven uses polyethylene with melting point 100-110°C. This melting point difference ensures that during heat treatment at temperatures below 100°C, the polypropylene reinforcing layer remains stable and prevents pleat adhesion while the polyethylene layer can still be heat-set
Solution Approach 2:
The oriented nonwoven fabric acts as an intermediary layer between the meltblown nonwoven and the pleating process. Its stable polypropylene structure serves as a barrier that prevents direct contact and adhesion between pleats during heat treatment, while still allowing the underlying structure to be shaped
3Productivity
If high processing wind speed is used, then processing efficiency is improved, but shape retention deteriorates
Solution Approach 1:
The invention performs preliminary reinforcement by attaching the oriented nonwoven fabric to the meltblown nonwoven before the pleating process. This pre-reinforcement creates a stable base structure that can withstand high processing wind speeds during manufacturing while maintaining the ability to hold the pleated shape after formation
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 provides a filter reinforcing material with improved stiffness, reduced pressure loss, and enhanced pleating properties, allowing for effective dust collection and shape retention, while utilizing the thermal bonded nonwoven to improve adhesive strength and filtration performance.
Implementation Method 1
a bonding layer comprising a thermal bonded nonwoven including thermal bondable short fibers
Implementation Method 2
a reinforcing layer comprising a nonwoven including high-melting fibers having a higher melting point than a melting point of the thermal bondable short fibers having the lowest melting point in the bonding layer by 30° C. or more
Data Source
AI summary
A filter reinforcing material is disclosed that does not cause peeling or pleat adhesion at the time of pleating, is excellent in pleating, and has high stiffness. A filter reinforcing material includes a bonding layer comprising a thermal bonded nonwoven including thermal bondable short fibers, and a reinforcing layer comprising a nonwoven including high-melting fibers having a higher melting point than a melting point of the thermal bondable short fibers having the lowest melting point in the bonding layer by 30° C. or more. Further, the bonding layer preferably comprises two or more kinds of thermal bondable short fibers with a fineness difference of more than or equal to 5 dtex.