Multilayered Filter Medium with Segmented Fiber Layers
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Solution Overview
Problem
Existing multilayered filter media face challenges in achieving a high air flow rate while maintaining high separation efficiency without excessive pressure loss, particularly in applications such as air filtration and fluid treatment.
Innovation Solution
A method for manufacturing a multilayered filter medium involving the formation of textile fabrics with specific polyester and melt binder fibers, followed by pre-solidification and calendering processes to enhance air permeability and filtration efficiency, including the introduction of the fabric into a hot-air oven for expansion, resulting in a filter medium with increased thickness and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the density of the filter medium is increased to improve separation efficiency, then the separation efficiency is improved, but the air flow rate decreases and pressure loss increases
Solution Approach 1:
The filter medium is divided into multiple layers with different fiber diameters and functions. The first layer contains fine fibers for high separation efficiency, while subsequent layers contain coarser fibers for maintaining air flow. This segmentation allows each layer to specialize in one function, resolving the contradiction between separation efficiency and air flow rate.
Solution Approach 2:
Different regions of the filter medium have different properties. The upstream layers have higher density and finer fibers optimized for particle capture, while downstream layers have lower density and coarser fibers optimized for air flow. This local differentiation allows the filter to achieve both high separation efficiency and high air flow rate simultaneously.
2Reliability
If the density of the filter medium is increased to improve separation efficiency, then the separation efficiency is improved, but the pressure loss increases
Solution Approach 1:
The filter medium is divided into multiple layers with different fiber diameters and functions. The first layer contains fine fibers for high separation efficiency, while subsequent layers contain coarser fibers for maintaining air flow. This segmentation allows each layer to specialize in one function, resolving the contradiction between separation efficiency and air flow rate.
Solution Approach 2:
Different regions of the filter medium have different properties. The upstream layers have higher density and finer fibers optimized for particle capture, while downstream layers have lower density and coarser fibers optimized for air flow. This local differentiation allows the filter to achieve both high separation efficiency and high air flow rate simultaneously.
3Productivity
If the air flow rate is increased to improve productivity, then the productivity is improved, but the separation efficiency decreases
Solution Approach 1:
The filter medium is divided into multiple layers with different fiber diameters and functions. The first layer contains fine fibers for high separation efficiency, while subsequent layers contain coarser fibers for maintaining air flow. This segmentation allows each layer to specialize in one function, resolving the contradiction between separation efficiency and air flow rate.
Solution Approach 2:
Different regions of the filter medium have different properties. The upstream layers have higher density and finer fibers optimized for particle capture, while downstream layers have lower density and coarser fibers optimized for air flow. This local differentiation allows the filter to achieve both high separation efficiency and high air flow rate simultaneously.
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 significantly increases air permeability by more than 50% and maintains high filtration efficiency, as demonstrated by the filter medium's ability to handle SAE dust of the 'fine' class with minimal pressure increase, achieving air permeability of at least 500 l/m2sec and suitable for various filtration applications.
Implementation Method 1
melt binder fibres consist of a polymer whose melting point is at least 5° C. below the melting point of the carrier fibres
Implementation Method 2
pre-solidification of the multilayered textile fabric formed in accordance with steps a) to c)
Implementation Method 3
Pre-solidification of the multilayered textile fabric formed in accordance with steps a) to c) by means of a heated roller whose surface temperature is at least 70° C.
Implementation Method 4
Calendering of the pre-solidified multilayered textile fabric formed in accordance with step g) by means of a calender whose surface temperature is at least 10° C. below the melting temperature of the melt binder fibres and a contact pressure/line pressure of at least 20 daN
Implementation Method 5
Introduction of the multilayered textile fabric calendered in accordance with step h) into a hot-air oven whose minimum temperature is equal to or above the melting temperature of the melt binder fibres and whose maximum temperature is at least 10° C. below the melting temperature of the carrier fibres wherein the introduced textile fabric expands and the thickness of the textile fabric increases by at least 30%
Data Source
AI summary
The present invention relates to a method for the manufacture of a multilayered filter medium whose air permeability is at least 500 l/m2sec and a multilayered filter medium obtainable by said method which, when charged with 5 mg/cm2 SAE-dust of the class “fine”, exhibits a pressure increase of no more than 100 Pa.