Nanofiber Filter Medium With Pre-Fixation for Flexible Production
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Solution Overview
Problem
Existing filter media production processes are limited by the sequential nature of nanofiber deposition and adhesive application, restricting flexibility and tying up production resources, as the nanofiber layer cannot be transported without immediate adhesive application.
Innovation Solution
A filter medium with a nanofiber layer connected to a substrate layer via adhesive and/or hot-melt adhesive fibers, utilizing an adhesion promoter layer to pre-fix the nanofibers, allowing spatial and temporal separation of deposition and adhesive application steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive and/or hot-melt adhesive fibers are applied immediately after nanofiber deposition, then the nanofiber layer is securely connected to the substrate layer, but the production process lacks flexibility and ties up capital unnecessarily
Solution Approach 1:
The patent applies a preliminary adhesion promoter layer to the substrate layer before nanofiber deposition. This preliminary action creates initial bonding sites that allow the nanofiber layer to be securely connected without requiring immediate adhesive application, enabling temporary storage and flexible scheduling of subsequent adhesive and hot-melt adhesive fiber steps
Solution Approach 2:
The patent introduces an adhesion promoter layer as an intermediary substance between the substrate layer and nanofiber layer. This intermediary provides initial adhesion that allows the nanofiber layer to be handled and stored temporarily, bridging the gap between deposition and final adhesive bonding without compromising connection reliability
2Stability of the object's composition
If adhesive and/or hot-melt adhesive fibers are applied in-line immediately after nanofiber deposition, then the nanofiber layer maintains connection stability, but system components must be immediately followed in-line by other system components
Solution Approach 1:
The adhesion promoter layer is applied in advance to the substrate layer, creating preliminary bonding capability before nanofiber deposition. This preliminary action eliminates the requirement for immediate in-line adhesive application, allowing independent positioning of production system components and reducing overall line complexity
Solution Approach 2:
The patent segments the production process into distinct stages: substrate preparation with adhesion promoter, nanofiber deposition, and separate adhesive/hot-melt adhesive fiber application. This segmentation allows each stage to be optimized and positioned independently, reducing the interdependence and complexity of in-line system configuration
3Ease of manufacture
If the nanofiber layer is deposited onto the substrate layer without preliminary adhesion treatment, then the deposition process is simple, but the nanofiber layer cannot be transported without immediate adhesive application
Solution Approach 1:
The adhesion promoter layer serves as an intermediary that enables transportability without complicating the deposition process. It is applied to the substrate layer before nanofiber deposition, providing the necessary bonding capability that allows the nanofiber layer to be handled and transported independently after deposition
Solution Approach 2:
The adhesion promoter is applied in advance to prepare the substrate layer for nanofiber deposition. This preliminary preparation maintains the simplicity of the deposition process itself while simultaneously enabling post-deposition transport and handling of the nanofiber layer
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
Enhances production flexibility and reduces costs by enabling separate processing steps, while providing mechanical protection and maintaining air permeability.
Implementation Method 1
An adhesion promoter layer is located between the nanofiber layer and the substrate layer, comprising an adhesion promoter applied over the entire surface of the substrate layer, wherein the nanofiber layer is fixed to the substrate layer by means of the adhesion promoter layer.
Implementation Method 2
The nanofiber layer is connected to the substrate layer via adhesive and/or hot-melt adhesive fibers, which are applied to the nanofiber layer formed after nanofibers have been deposited on the substrate layer. The adhesive and/or hot-melt adhesive fibers are designed such that they, on the one hand, penetrate the nanofiber layer and establish the connection between the nanofiber layer and the substrate layer
Implementation Method 3
adhesive and/or hot-melt adhesive fibers
Implementation Method 4
The hot melt adhesive fibers arranged superficially on the nanofiber layer according to the present invention provide effective protection, e.g., as a grip protection, i.e., protection against abrasion of the nanofibers, due to the fact that the hot melt adhesive fibers protrude from the nanofibers.
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a filter medium (1) comprising a substrate layer (2) and a nanofiber layer (3), wherein the nanofiber layer (3) is connected to the substrate layer (2) by adhesive and/or hot-melt adhesive fibers (4) that penetrate the nanofiber layer. The nanofiber layer (3) is located in the sequence of layers between the substrate layer (2) and the adhesive and/or hot-melt adhesive fibers (4). An adhesion promoter layer (6) is located between the nanofiber layer (3) and the substrate layer (2), comprising an adhesion promoter applied over the entire surface of the substrate layer (2), wherein the nanofiber layer (3) is fixed to the substrate layer (2) by means of the adhesion promoter layer (6). Furthermore, a method for producing the filter medium (1) and a use of the filter medium (1) are disclosed.