Low-Melting Polyester Cabin Filter Fabric with Binder-Free Bonding
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Solution Overview
Problem
Conventional cabin air filters face issues with secondary pollution and chemical toxicity due to the use of binder polymers and chemical antibacterial agents, leading to bacterial growth and reduced filtration efficiency, while existing methods for improving antibacterial properties in HEPA filters are inadequate and may cause indoor air pollution.
Innovation Solution
A nonwoven fabric for cabin air filters using a combination of high and low melting point polyester fibers, where the low melting point fibers include illite particles and silver-based inorganic antibacterial agents, enhancing thermal adhesive properties and antibacterial performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If binder polymer solution is used to fixate antibacterial agents or deodorizing powders to nonwoven fabric, then the antibacterial agents or deodorizing powders are prevented from separating, but the binder polymer causes secondary pollution, clogs pores, and allows bacterial growth
Solution Approach 1:
The patent extracts and eliminates the binder polymer from the system by using a thermal bonding process that directly bonds fibers through heat and pressure without requiring any binding agents. The low melting point polyester fibers are melted and bonded to high melting point fibers through thermal compression, achieving fixation without harmful binders.
Solution Approach 2:
The patent introduces thermal energy as an intermediary to achieve fiber bonding. By applying heat, the low melting point polyester fibers transition to a molten state and bond with high melting point fibers, serving as a mediator that enables fixation without chemical binders.
2Reliability
If chemical antibacterial agents are used in cabin air filters, then antibacterial function is provided, but toxicity and secondary pollution occur
Solution Approach 1:
The patent replaces persistent chemical antibacterial agents with a physical antibacterial mechanism based on silver ions. Silver particles are incorporated into the nonwoven fabric structure, providing long-lasting antibacterial protection through ion release without the toxicity and secondary pollution associated with chemical antibacterial agents.
Solution Approach 2:
The patent changes the fundamental mechanism of antibacterial action from chemical to physical/ionic. By incorporating silver particles that release silver ions, the system provides antibacterial function through a different parameter (ionic interaction) rather than chemical reaction, eliminating toxicity and secondary pollution.
3Strength
If low melting point fibers are used for thermal bonding, then fiber adhesion is achieved, but deodorizing powder flows inside the web and aggregates on the bottom surface
Solution Approach 1:
The patent uses a composite structure combining low melting point polyester fibers (for thermal bonding) with high melting point fibers (to provide structural support). This composite approach allows thermal adhesion through the low melting point fibers while the high melting point fibers maintain the web structure and prevent powder aggregation.
Solution Approach 2:
The patent applies different properties to different parts of the nonwoven fabric system. Low melting point fibers are used specifically for bonding areas where adhesion is needed, while high melting point fibers are distributed throughout to maintain structural integrity and prevent powder flow, creating local quality differences that solve the contradiction.
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 nonwoven fabric achieves improved dust capture and antibacterial properties with high strength at high temperatures, minimizing secondary pollution and maintaining effective filtration efficiency.
Implementation Method 1
a first polyester fiber containing a polyester resin having a melting point higher than 250°C. and a second polyester fiber containing a low melting point polyester resin having a softening point of 100 to 150°C.
Implementation Method 2
the second polyester fiber includes a low melting point polyester resin which is formed from an acid component included of terephthalic acid or ester-forming derivatives thereof, and a diol component included of 2-methyl-1,3-propanediol, 2-methyl-1,3-pentanediol, and ethylene glycol, and the second polyester fiber contains illite particles, i.e., micaceous mineral, or a mixture of the illite particles and sericite particles, and silver-based inorganic antibacterial agent particles.
Data Source
AI summary
The present invention relates to a nonwoven fabric for cabin air filter including a low melting point polyester fiber, in which the nonwoven fabric for cabin air filter includes a first polyester fiber containing a polyester resin having a melting point higher than 250° C. and a second polyester fiber containing a low melting point polyester resin having a softening point of 100 to 150° C., the first polyester fiber is a modified cross-sectional yarn having a roundness of 50 to 80%, the second polyester fiber includes a low melting point polyester resin which is formed from an acid component included of terephthalic acid or ester-forming derivatives thereof, and a diol component included of 2-methyl-1,3-propanediol, 2-methyl-1,3-pentanediol, and ethylene glycol, and the second polyester fiber contains illite particles, i.e., micaceous mineral, or a mixture of the illite particles and sericite particles, and silver-based inorganic antibacterial agent particles.