Multi-ply Filter Medium for Compact Air Filtration
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Solution Overview
Problem
Conventional filter systems in supply air and heat exchanger systems are complex and require significant space, with high maintenance needs due to the use of multiple filter classes, necessitating a more compact and efficient filtration solution.
Innovation Solution
A multi-ply filter medium comprising a textile stiffening layer, a filtration layer made of glass fibers, and a cover layer of synthetic polymer fibers, with specific weight and air permeability characteristics, consolidated using chemical or thermoplastic binders, to create a compact filter with enhanced filtration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate filter classes are used in supply air and heat exchanger systems, then filtration performance is improved, but device complexity and space requirement increase
Solution Approach 1:
The patent combines multiple filter classes (coarse, medium, and fine filtration) into a single multi-ply filter medium. The filter medium comprises a first ply with coarse filtration capability, a second ply with medium filtration capability, and a third ply with fine filtration capability, all integrated into one structure. This merging eliminates the need for multiple separate filter installations, reducing system complexity while maintaining comprehensive filtration performance.
Solution Approach 2:
The filter medium is segmented into multiple functional plies, each with specific filtration characteristics. The first ply (coarse), second ply (medium), and third ply (fine) are distinct layers with different fiber compositions and structures, allowing each to perform its specific filtration function while working together as an integrated system.
2Reliability
If multiple separate filter classes are used, then filtration performance is improved, but space requirement increases
Solution Approach 1:
Multiple filter classes are merged into a single multi-ply filter medium structure, where the first, second, and third plies are laminated together. This integration reduces the space required from multiple separate filter installations to a single compact filter unit, while maintaining the cumulative filtration performance of all three filter classes.
Solution Approach 2:
The filter plies are nested in a layered structure where each ply is positioned within the overall filter medium assembly. The first ply, second ply, and third ply are arranged in sequence, with each layer contributing its filtration capability within the compact nested structure of the single filter unit.
3Reliability
If multiple separate filter classes are used, then filtration performance is improved, but maintenance outlay increases
Solution Approach 1:
The patent merges multiple filter classes into a single replaceable filter medium, eliminating the need to maintain and replace multiple separate filters. The integrated first, second, and third plies function as one unit, reducing maintenance complexity and outlay while providing comprehensive filtration across coarse, medium, and fine particle sizes.
4Area of stationary object
If a compact filter design is implemented, then space requirement is reduced, but filtration efficiency may be compromised
Solution Approach 1:
Each ply in the multi-ply filter medium has locally optimized properties tailored to its specific filtration function. The first ply is designed with characteristics optimal for coarse filtration, the second ply for medium filtration, and the third ply for fine filtration. This local quality optimization ensures high filtration efficiency at each stage while maintaining a compact overall structure.
Solution Approach 2:
The filter medium uses composite material construction with three different plies, each made from appropriately selected synthetic fibers or glass fibers with specific properties. This composite structure allows the compact filter to achieve high filtration efficiency by combining the strengths of different materials in a layered configuration.
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 solution provides a compact filter design with improved filtration efficiency and reduced maintenance requirements, suitable for use in supply air and heat exchanger systems, while maintaining effective air and liquid filtration capabilities.
Implementation Method 1
consolidated using chemical or thermoplastic binders
Implementation Method 2
consolidated using chemical or thermoplastic binders
Data Source
AI summary
The present invention relates to a filter composed of a multi-ply filter medium which (i) has at least one textile stiffening layer (layer 4), preferably a non-woven layer, of synthetic, polymer fibers, glass fibers or mixtures of the same, (ii) at least one filtration layer (layer 3), which is attached to at least one side of the non-woven stiffening fabric, the filtration layer being made up of glass fibers, (iii) at least one further filtration layer (layer 2), which is applied on the filtration layer according to ii), the further filtration layer being made up of glass fibers, and at least one textile cover layer (layer 1), which is applied on the filtration layer according to (iii), the cover layer being made up of synthetic polymer fibers. A further subject matter are filter modules including a housing and at least one filter medium according to the invention, and also a method for producing the filter medium according to the invention and also the filter modules and the use thereof in filtration of air/gas and liquids, preferably for filtration of air flows in supply air and/or heat exchanger systems.