Multi-Layer Filter Bag Insert to Prevent Outer Layer Clogging
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Solution Overview
Problem
Existing vacuum cleaner filter bags experience reduced suction power due to clogging of outer filter material layers with dust, limiting their dust storage capacity and volume flow efficiency.
Innovation Solution
A filter bag design featuring a middle layer for dust collection, surrounded by outer layers of higher strength, which acts as a pre-filter to prevent dust from clogging the outer layers, and can expand and tear apart to maintain suction power as dust accumulates, allowing for a three-dimensional shape formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the filter bag is filled with dust to increase dust storage capacity, then the dust holding capacity is improved, but the outer filter material layers become clogged resulting in decreased volume flow and suction power
Solution Approach 1:
The filter insert is divided into three functional layers: two outer layers for structural integrity and dust intake, and a middle layer for dust accumulation. This segmentation allows dust to be captured in the middle layer without blocking the outer filter material layers of the bag, resolving the contradiction between dust storage capacity and airflow maintenance
Solution Approach 2:
The filter insert acts as an intermediary dust reservoir between the inlet opening and the outer filter material layers. Dust-laden air flows through the outer layers into the filter insert where dust accumulates in the middle layer, preventing direct clogging of the outer layers and maintaining volume flow while increasing dust storage capacity
2Ease of manufacture
If a flat partition is integrated into the vacuum cleaner bag to increase dust holding capacity, then the manufacturing effort is limited, but the dust holding capacity remains limited
Solution Approach 1:
The filter insert transitions from a flat state during manufacturing to a three-dimensional, bag-like shape during use as the middle layer expands with dust accumulation. This dynamic transformation allows easy integration during manufacturing while achieving large dust holding capacity during operation
Solution Approach 2:
The physical state of the filter insert changes from flat (low volume) to three-dimensional (high volume) as dust accumulates in the middle layer. This parameter change in shape and volume enables easy manufacturing integration while providing expanded dust holding capacity when needed
3Quantity of substance
If the middle layer becomes loaded with dust causing expansion, then the dust storage capacity is improved, but the outer layers may be damaged if not sufficiently strong
Solution Approach 1:
Different layers are assigned different mechanical properties: the outer layers have high tensile strength (50% higher than the middle layer) to resist damage from middle layer expansion, while the middle layer has softer, more compliant properties to expand and accommodate dust accumulation. This local differentiation of material quality resolves the contradiction between dust storage capacity and structural strength
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 design significantly enhances dust storage capacity and maintains suction power by preventing outer layer clogging, with the middle layer collecting dust and expanding to accommodate increased dust loads, ensuring the filter bag remains effective even when filled.
Implementation Method 1
a filter insert (7), which is at least partially connected to the first and/or second filter material layer (2, 3), is arranged in the interior space (6)... a middle layer (10) which is provided between the outer layers (9, 11) for dust accumulation
Implementation Method 2
The outer layer (9) has at least one opening (8) on the side facing the inlet opening (4) for dust-laden air to flow into the middle layer (10)
Implementation Method 3
The opening on the side of the outer layer facing the inlet can be formed by a predetermined breaking point that tears open during use
Implementation Method 4
The filter insert can be made of spunbond, the outer layers of which are thermally bonded
Data Source
Figure 1A~2
Figure 3A~3C
Figure 4A~4C
AI summary
A filter bag (1), in particular for vacuum cleaners, comprises a first filter material layer (2) with an inflow opening (4) and a second filter material layer (3) which is connected at the edge to the first filter material layer (2) to form an interior space (6), wherein a flat, multi-layer filter insert (7, 7', 7") connected at least partially to the first and/or second filter material layer is arranged in the interior (6), the filter insert (7, 7', 7") having at least two outer layers (9 , 11), between which a middle layer (10) or an intermediate space is provided for loading with dust. This increases the dust storage capacity