Method for manufacturing filter edge band non-woven fabric
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Solution Overview
Problem
Conventional filter edge band frames are manufactured using a costly and complex process involving chemical binder resins, which can separate during use, block filter pores, and pose environmental concerns.
Innovation Solution
A method of manufacturing a filter edge band non-woven fabric using needle-punched sheath-core type thermal bonding composite fibers, composed of low-melting-point and high-melting-point polyesters, which are heat-treated to produce a durable and environmentally friendly fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder resin treatment is used to manufacture edge band frame, then adhesion strength is improved, but manufacturing complexity increases and environmental harm occurs
Solution Approach 1:
The invention extracts and eliminates the binder resin component from the edge band frame structure, replacing chemical adhesion with mechanical interlocking through the hollow spherical filler particles that physically entangle with the non-woven fabric fibers, thereby simplifying the manufacturing process while maintaining adhesion strength
Solution Approach 2:
The hollow spherical filler particles act as intermediaries between the non-woven fabric layers, providing mechanical interlocking and adhesion without requiring chemical binders, thus resolving the contradiction between strength and manufacturing simplicity
2Stability of the object's composition
If chemical binder resin is used in edge band frame, then structural stability is improved, but harmful factors increase due to resin separation and pore blockage
Solution Approach 1:
The invention converts the potential harm of loose filler particles into a beneficial structural component by using hollow spherical particles that provide mechanical interlocking and structural stability without the negative effects of chemical resin separation and pore blockage
Solution Approach 2:
The invention changes the physical and chemical parameters of the filler material from chemical binder resin to inorganic hollow spherical particles with specific density and size characteristics, eliminating harmful chemical properties while maintaining structural stability
3Object-generated harmful factors
If thermal bonding composite fibers are used, then environmental friendliness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The invention changes the bonding mechanism from chemical to thermal-physical by using temperature-controlled thermal bonding that melts the polyester fibers at specific temperatures to create strong bonds without requiring precise chemical composition control, thus maintaining environmental friendliness while managing manufacturing precision requirements
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 method produces a filter edge band non-woven fabric that maintains thickness, air permeability, and morphological stability, making it suitable for various filter applications without the need for chemical binder resins.
Implementation Method 1
needle-punching sheath-core type thermal bonding composite fibers, each composed of a sheath portion comprising a low-melting-point polyester and a core portion comprising a high-melting-point polyester
Implementation Method 2
heat-treating the produced needle-punched non-woven fabric
Data Source
AI summary
The present invention relates to a method for manufacturing a filter edge band non-woven fabric, and more specifically, to a method for manufacturing an environmentally-friendly filter edge band non-woven that replaces an environmentally harmful filter edge band treated with a chemical binder resin.