Filter and method for manufacturing same
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Solution Overview
Problem
Existing nanofiber filters face issues such as decreased dust collection efficiency over time due to electrostatic force reduction, uneven nanofiber adhesion, and susceptibility to physical and chemical damage, along with non-uniform diameters and lack of antibacterial and photodecomposition effects.
Innovation Solution
A nanofiber filter with a conductive base, incorporating conductive materials like copper or antibacterial metal oxides, and a protective layer with antibacterial agents and photocatalysts, is manufactured by electrospinning onto a conductive base functioning as the electrode, ensuring uniform nanofiber attachment and enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dielectric non-woven fabric collector is used, then nanofibers can be collected, but nanofibers are unevenly attached due to surface curvature and polarity in electric field
Solution Approach 1:
The patent applies homogeneity by using a conductive material as the collector that provides uniform electrical properties across its surface. This eliminates the polarity variations and surface curvature effects that cause non-uniform nanofiber attachment when using dielectric materials. The conductive collector ensures consistent electric field distribution, resulting in uniform nanofiber deposition.
2Reliability
If electrospinning is used to manufacture filter, then nanofibers can be produced, but electrostatic force decreases due to moisture contact and organic substance adhesion
Solution Approach 1:
The patent converts the harmful effect of moisture and organic substances that normally degrade electrostatic force into a beneficial outcome. By using a conductive collector, the system allows controlled dissipation of electrostatic charge, preventing the buildup that leads to uneven nanofiber attachment while maintaining sufficient electrostatic attraction for dust collection. The conductive material manages electrostatic forces rather than allowing them to degrade performance over time.
3Object-generated harmful factors
If IPA post-processing is used to remove electrostatic force, then electrostatic force is reduced, but filter is damaged and efficiency is reduced
Solution Approach 1:
The patent extracts the harmful electrostatic force buildup by using a conductive collector that allows controlled charge dissipation. Instead of applying IPA to remove electrostatic force after filter manufacturing (which damages the filter), the conductive collector continuously manages electrostatic charges during operation, eliminating the need for chemical treatment and preserving filter integrity and efficiency.
4Adaptability or versatility
If nanofibers are spun with varying parameters, then production flexibility is improved, but nanofiber diameter uniformity deteriorates
Solution Approach 1:
The conductive collector provides a uniform electrical environment that stabilizes the electrospinning process. Even when spinning parameters vary for different production requirements, the homogeneous conductive surface ensures consistent electric field distribution, maintaining nanofiber diameter uniformity across different operating conditions and polymer solutions.
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 maintains consistent dust collection efficiency, achieves uniform nanofiber diameters, provides antibacterial and photodecomposition effects, and minimizes physical and chemical damage, while preventing electrostatic charge buildup.
Implementation Method 1
a high voltage applied from a high voltage source HV. Spun nanofibers 2 are collected on a collector 6 placed between the nozzle 5 and the ground electrode 9
Implementation Method 2
a base having conductivity... the conductive material may be an antibacterial metal or an antibacterial metal oxide
Data Source
AI summary
A filter and a method for manufacturing same are disclosed. The filter including nanofibers formed by electrospinning comprises: a base having conductivity; and a nanofiber web formed by attaching the nanofibers on the base. The method for manufacturing the filter by attaching nanofibers on a base comprises the steps of: filling a syringe having a nozzle with a polymer solution, which is a raw material of the nanofibers; applying a +high voltage to the nozzle; and spinning the nanofibers from the nozzle toward the base. The base functions as a counter electrode of the nozzle.