Nanoweb Substrate Laminate Delamination Resistance

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Solution Overview

Problem

Existing laminated filter media used in dust collectors delaminate easily during reverse pulse cleaning due to stress caused by repeated expansion and retraction, leading to inefficiencies and reduced durability.

Innovation Solution

A process of adhesively laminating a low basis weight nanoweb to a substrate using a carrier layer and a patterned adhesive application, ensuring secure bonding and enhanced durability, which withstands multiple cycles of air jet pulsing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If reverse pulse cleaning is used to clean filter media, then filtration efficiency is maintained, but the filter media delaminates due to stress from repeated expansion and retraction

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidlaminate integrity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The filter media is segmented into distinct functional layers: a top layer of nanofibers for filtration and a bottom layer of substrate for structural support and cleaning durability. This segmentation allows each layer to perform its specific function optimally while being bonded through adhesive regions, resolving the contradiction between maintaining filtration efficiency and preventing delamination during cleaning cycles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Adhesive regions are pre-formed between the nanofiber layer and substrate before the filter media undergoes cleaning cycles. This preliminary bonding action ensures that when reverse pulse cleaning causes expansion and retraction, the layers remain securely attached, preventing delamination while maintaining the ability to perform filtration efficiently.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a nanoweb with basis weight less than 2 gsm is used, then filtration efficiency is improved, but the nanoweb lacks sufficient strength and is difficult to handle

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidnanoweb strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The weak nanoweb layer is merged with a strong substrate layer through adhesive bonding. The nanofiber layer provides superior filtration efficiency due to its low basis weight and fine pore structure, while the substrate layer provides the mechanical strength and handleability needed for practical application. This merging resolves the contradiction between achieving high filtration efficiency and maintaining sufficient strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The filter media is constructed as a composite material system combining nanofibers bonded to a substrate. This composite structure allows the nanofiber component to optimize filtration performance with minimal weight, while the substrate component provides the necessary mechanical properties. The adhesive bonding creates a unified composite that exhibits both high filtration efficiency and adequate strength.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If adhesive is applied to bond nanoweb to substrate, then delamination resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedelamination resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Adhesive is applied in specific local regions rather than uniformly across the entire surface. The adhesive regions are positioned at optimal locations to provide sufficient bonding strength and delamination resistance while minimizing the total amount of adhesive used and simplifying the application process. This local quality approach resolves the contradiction between achieving delamination resistance and maintaining manufacturing simplicity.

Inventive Principle:

Principle #3Local quality

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 resulting composite filter media exhibits improved resistance to delamination, high filtration efficiency, and maintains strength characteristics, allowing for efficient and economical production.

Implementation Method 1

applying a layer of adhesive to at least a portion of one surface of the substrate, contacting the adhesive layer with the nanoweb and bonding the nanoweb to the substrate

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

providing a carrier layer having a collection surface, forming a nanoweb on the collection surface of the carrier layer

Methodology Applied

Scientific EffectSurface adhesion: Adhesive

Data Source

PatentEP2152507B2Process for forming a laminate of a nanoweb and a substrate, and filters utilizing the laminate

Publication Date: 2019.02.27 EI DU PONT DE NEMOURS & CO

AI summary

A process for forming a laminate of a low basis weight nanoweb and a substrate includes forming a nanoweb on the surface of a collection scrim, and subsequently bringing the nanoweb into contact with a substrate coated with adhesive. The laminate is suitable for use as a gas filtration medium.