High Density Filter Paper With Heat-Deformed Rigid Ribs
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Solution Overview
Problem
Conventional air filters, particularly those using non-woven fabric and filter paper, have complex structures, high costs, and environmental concerns due to non-recyclable parts, with filter paper versions being prone to durability issues when exposed to water and foreign materials, leading to increased service and environmental pollution.
Innovation Solution
The use of high-density filter paper with a thermally bonded non-woven fabric structure featuring a dense layer of polyethylene terephthalate fibers, which is heat-deformed to create a '–shaped rigid rib for increased rigidity and reduced ventilation resistance, allowing for recyclable parts and a simpler structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If non-woven fabric filter paper with binder bonding is used to prevent deformation, then shape stability is improved, but device complexity and cost increase due to rubber seals, plastic frames, and fixing shafts
Solution Approach 1:
The invention extracts and removes the plastic frame and fixing shaft components from the air filter assembly. The filter paper itself is designed with self-supporting rigid ribs that eliminate the need for these separate structural components, thereby simplifying the overall device structure while maintaining shape stability.
Solution Approach 2:
The invention merges the structural support function into the filter paper itself by incorporating rigid ribs directly into the paper structure. This integration eliminates the need for separate plastic frames and fixing shafts, combining multiple functions into a single component.
2Device complexity
If filter paper is used to simplify structure and reduce cost, then device complexity is reduced, but reliability deteriorates when exposed to water or foreign materials causing deformation
Solution Approach 1:
The invention applies local quality by creating rigid ribs at specific locations within the filter paper structure. These localized rigid sections provide structural support and resistance to deformation where needed, while the rest of the filter paper maintains its filtering functionality. The rigid ribs are strategically positioned to prevent collapse without compromising overall filter performance.
3Stability of the object's composition
If binder bonding is used to bond fibers in non-woven fabric, then shape stability is improved, but environmental harm increases due to non-recyclable parts
Solution Approach 1:
The invention enables recovery and recycling of the filter paper by eliminating binder materials that prevent recycling. The mechanical bonding through rigid ribs allows the filter paper to maintain its shape while being fully recyclable, thus reducing environmental pollution from non-recyclable parts.
4Stability of the object's composition
If rigid structure is added to prevent deformation, then shape stability is improved, but air permeability decreases due to increased ventilation resistance
Solution Approach 1:
The invention applies partial action by implementing rigid ribs only in specific strategic locations within the filter paper rather than making the entire structure rigid. This selective reinforcement provides necessary shape stability while leaving other areas open and permeable for optimal air flow, thus balancing structural support with ventilation efficiency.
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
This solution reduces costs, weight, and replacement costs while enhancing durability and air permeability, allowing for the recycling of plastic frames and shafts, thereby minimizing environmental pollution and improving the air filtration efficiency.
Implementation Method 1
a wrinkle portion continued by virtue of thermally bonded non-woven fabric filter paper having a dense layer deformed by heat
Data Source
AI summary
Disclosed is an air filter using high density filter paper. The filter paper may include a thermally bonded non-woven fabric filter paper 10 having air permeability to filter foreign materials of passed polluted air and change the polluted air to fresh air. The non-woven fabric filter paper includes wrinkled portions 10-1 and 10-N that are folded at a predetermined interval. A thickness of the wrinkle portions 10-1 and 10-N are provided with dense layers 15 and 17 comprising a first polyethylene terephthalate (PET) fiber 20-2 that can shrink by heat and a second polyethylene terephthalate (PET) fiber 20-1 that deforms upon by heat treatment.