Intermeshed Fibrous Filter Media for Thin, High-Permeability Filtration
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Solution Overview
Problem
Existing filter media face challenges in achieving high air permeability, dust absorption, and mechanical properties while maintaining low thickness and cost-effectiveness, particularly in low velocity air flow situations, often requiring multiple manufacturing steps and expensive additives.
Innovation Solution
A fibrous layer comprising two intermeshed portions with a weight ratio of synthetic to cellulosic fibers, created together through a single manufacturing process, such as wet laying, to enhance permeability and dust absorption without increasing thickness or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers with different properties are created to improve filtration performance, then filter efficiency and dust absorption are improved, but filter thickness increases and manufacturing complexity increases
Solution Approach 1:
The filter medium is divided into two distinct portions within a single layer: a first portion with higher synthetic fiber content for mechanical strength and a second portion with higher cellulosic fiber content for dust absorption. This segmentation allows different functional zones to coexist without increasing overall thickness.
Solution Approach 2:
Different regions of the filter medium have different fiber compositions tailored to specific functions. The first portion uses more synthetic fibers for structural integrity, while the second portion uses more cellulosic fibers for filtration performance, optimizing local properties for specific needs.
2Reliability
If multiple layers are created with different properties, then filtration performance is improved, but manufacturing complexity and process steps increase
Solution Approach 1:
Two portions that would traditionally require separate layer formation and bonding processes are merged into a single layer formed in one continuous manufacturing process. The wet laying process deposits both portions simultaneously, eliminating the need for separate adhesive bonding steps.
Solution Approach 2:
A single manufacturing process serves multiple functions: it forms both portions of the filter medium, creates the interface between them, and eliminates the need for separate bonding operations. This multi-functional approach simplifies the overall manufacturing system.
3Reliability
If expensive additives are introduced to alter filter properties, then air permeability and dust absorption are improved, but manufacturing cost increases
Solution Approach 1:
Instead of adding expensive chemical additives to modify filter properties, the invention changes the physical parameters of the fiber composition. By adjusting the ratio and distribution of synthetic and cellulosic fibers, the desired air permeability and dust absorption characteristics are achieved through material selection rather than chemical modification.
Data Source
AI summary
Filter media, filters and methods for making the same are provided herein. A filter media comprises a fibrous layer having a first portion and a second portion, the first portion and second portions being disposed next to each other along a thickness direction of the layer. The fibers from the first portion are intermeshed with the fibers from the second portion. A weight ratio of the fibers in the first portion to the fibers in the second portion is greater than 1:1. In certain embodiments, the fibrous layer comprise synthetic fibers, and two different types of cellulosic fiber. The synthetic fibers constitute less than 20 wt % of the fibers in the fibrous layer, and the second portion comprises more synthetic fibers, in terms of mass per unit area, than the first portion.