Meltblown Filter Medium Layering for Dust Capacity and Efficiency

Solution Overview

Problem

Conventional filter media often struggle to simultaneously achieve high dust holding capacity, fine particle capture efficiency, and durability, while also maintaining effective cleanability and liquid filtration properties.

Innovation Solution

A filter medium comprising a substrate layer with high air permeability and a meltblown material layer, where the meltblown layer is positioned downstream of the substrate, providing a dust holding capacity of at least 70 g/m² and an initial dust capture efficiency of at least 90% for 10 micron particles, along with good cleanability and liquid filtration efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If conventional filter media are used to achieve high dust holding capacity, then dust holding capacity is improved, but fine particle capture efficiency deteriorates

Engineering Contradiction:

Improvedust holding capacityVSAvoidfine particle capture efficiency

Core Design Contradiction:

Quantity of substanceVSMeasurement precision

Solution Approach 1:

The filter medium is divided into multiple layers with distinct functions: a first layer (substrate) providing structural support and high air permeability, and a second layer (meltblown material) providing fine particle capture. This segmentation allows each layer to optimize for its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filter medium combines different materials with complementary properties: a substrate material (such as polyester or polypropylene) for mechanical strength and permeability, and a meltblown material (such as polyolefin fibers) for fine particle filtration. This composite structure achieves both high dust holding capacity and high fine particle capture efficiency.

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If filter media are designed for high dust holding capacity, then dust holding capacity is improved, but cleanability deteriorates

Engineering Contradiction:

Improvedust holding capacityVSAvoidcleanability

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The filter medium utilizes porous structures with controlled pore sizes and distributions. The substrate layer provides large pores for high air permeability and dust storage, while the meltblown layer provides smaller pores for fine particle capture. The porous structure allows dust to be held within the matrix while maintaining pathways for air flow and facilitating cleaning through pulse jet or reverse airflow.

Inventive Principle:

Principle #31Porous materials

3Measurement precision

If filter media are designed for fine particle capture, then fine particle capture efficiency is improved, but air permeability deteriorates

Engineering Contradiction:

Improvefine particle capture efficiencyVSAvoidair permeability

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The filter medium is divided into multiple layers with distinct functions: a first layer (substrate) providing structural support and high air permeability, and a second layer (meltblown material) providing fine particle capture. This segmentation allows each layer to optimize for its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

4Quantity of substance

If filter media are designed for high dust holding capacity, then dust holding capacity is improved, but durability deteriorates

Engineering Contradiction:

Improvedust holding capacityVSAvoiddurability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The filter medium combines different materials with complementary properties: a substrate material (such as polyester or polypropylene) for mechanical strength and permeability, and a meltblown material (such as polyolefin fibers) for fine particle filtration. This composite structure achieves both high dust holding capacity and high fine particle capture efficiency.

Inventive Principle:

Principle #40Composite materials

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 filter medium effectively captures fine particles, holds significant dust, and maintains cleanability and filtration efficiency, offering a durable solution that combines these properties typically not simultaneously achieved by known filter media.

Implementation Method 1

The filter medium includes a first, substrate layer facing the inlet, the substrate layer having an air permeability of at least 70 CFM... The filter medium may also include a second layer comprising a meltblown material positioned downstream of the first layer

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS8986432B2Meltblown filter medium, related applications and uses

Publication Date: 2015.03.24 HOLLINGSWORTH & VOSE COMPANY

AI summary

Filter media, as well as related assemblies, systems and methods. Filter media may contain one or more layers formed of a meltblown material.