Gradient Glass Fiber Filter Media for M6 Filtration Strength
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Solution Overview
Problem
Existing filter sheet media for air and gas filtering applications are costly and require high amounts of micro glass fibers, leading to inefficient production and reduced tensile strength, while failing to meet high filtration standards like EN779:2012 class M6 without compromising on manufacturing costs.
Innovation Solution
A filter sheet media composition comprising a first group of glass fibers with diameters between 6 μm to 20 μm and a second group of glass fibers with diameters between 0.2 μm to less than 6 μm, distributed in a gradient structure across the thickness, using a foam forming process to reduce micro glass fiber content and enhance tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high amounts of micro glass fibers are used to meet EN779:2012 class M6 filtration standards, then filtration performance is improved, but manufacturing costs increase and tensile strength decreases
Solution Approach 1:
The patent applies local quality by creating a gradient structure where micro glass fibers are distributed non-uniformly across the filter sheet thickness. The concentration of second group glass fibers (0.2-6 μm) is highest at the first surface and gradually decreases toward the second surface, while first group glass fibers (6-20 μm) provide structural support throughout. This localized distribution optimizes filtration performance at the inlet surface while maintaining overall tensile strength through the binder network and coarser fiber framework.
Solution Approach 2:
The patent uses composite materials by combining two distinct groups of glass fibers with different diameter ranges (first group: 6-20 μm, second group: 0.2-6 μm) in a gradient arrangement. This composite structure leverages the fine filtration capability of micro glass fibers at the inlet surface while the coarser first group fibers provide mechanical strength, creating a synergistic material system that meets both filtration and strength requirements.
2Reliability
If high amounts of micro glass fibers are used to achieve high filtration efficiency, then filtration performance is improved, but production efficiency decreases due to costly manufacturing
Solution Approach 1:
The gradient structure concentrates micro glass fibers (second group) primarily at the first surface where particle capture is most critical, rather than distributing them uniformly throughout the entire sheet. This localized placement maximizes filtration efficiency at the inlet while reducing the total quantity of expensive micro glass fibers required, thereby improving production efficiency and reducing manufacturing costs.
Solution Approach 2:
The patent changes the distribution parameter of micro glass fibers from uniform to gradient-based concentration. By controlling the fiber distribution gradient across the thickness direction, the invention optimizes the balance between filtration efficiency (requiring fine fibers) and production cost (reducing total micro fiber content), achieving class M6 performance with more economical material usage.
3Ease of manufacture
If uniform distribution of glass fibers is used in filter sheet media, then manufacturing simplicity is maintained, but filtration performance is suboptimal
Solution Approach 1:
The patent implements local quality through a gradient distribution of the second group of glass fibers, where the concentration varies across the thickness direction with highest density at the first surface and decreasing toward the second surface. This non-uniform arrangement is achieved through controlled fiber suspension and web formation processes that maintain manufacturing feasibility while dramatically improving filtration performance compared to uniform distributions.
Data Source
AI summary
A filter sheet media (1) for air/gas filtering applications fulfilling the criteria of standard EN779:2012 class M6 filter media, the filter sheet media (1) comprises: a first group of glass fibers (20) having a fiber diameter in a range of greater or equal to 6 μm up to 20 μm; a second group of glass fibers (30) having a fiber diameter in a range of 0.2 μm to less than 6 μm; a binder (40); the second group of glass fibers (30) have a fiber distribution gradient over the thickness (13) of the filter sheet media (1) so that the second group of glass fibers (30) are distributed through the thickness (13) of the filter sheet media (1), the filter sheet media (1) having more second group of glass fibers (30) near the first surface (11) than the second surface (12). Also disclosed is a method for manufacturing.