Non-woven fabric and filter using same
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Solution Overview
Problem
Existing non-woven fabrics used for filters in range hoods and ventilation fans face issues with non-uniform flame retardancy, reduced air permeability, and insufficient stiffness, which affect their performance in preventing stains and maintaining shape during mounting.
Innovation Solution
A non-woven fabric with a composite polyester fiber core-sheath structure, where the sheath is low melting point polyester and the core is high melting point polyester, integrated with other fibers, providing sufficient bonding, stiffness, and elasticity, along with flame retardancy, achieved through a specific manufacturing process involving heat bonding and reheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a binder is applied to the surface layer of the non-woven fabric for flame retardancy, then flame retardancy is improved, but the binder does not sufficiently penetrate to the inner side resulting in non-uniform flame retardancy
Solution Approach 1:
The patent changes the physical state parameter of the binder from liquid (spray application) to solid particles (powder coating), enabling uniform distribution and penetration throughout the non-woven fabric layers, achieving uniform flame retardancy throughout the material
Solution Approach 2:
The patent replaces the chemical bonding mechanism (binder adhesion) with a thermal bonding mechanism (heat fusion of thermoplastic particles), eliminating the need for liquid binder penetration while achieving uniform flame retardancy through particle distribution
2Reliability
If a large amount of binder is penetrated to the inner side to improve flame retardancy, then flame retardancy is improved, but air permeability is reduced due to filling or narrowing gaps between fibers
Solution Approach 1:
The patent changes the binder from a liquid adhesive to solid thermoplastic particles that bond through heat fusion, allowing flame retardant particles to be distributed throughout the fabric without the volume displacement problem of liquid binders, thus maintaining air permeability
Solution Approach 2:
The patent utilizes the phase transition of thermoplastic particles from solid to molten state during heat bonding, allowing the particles to flow into fiber gaps and bond fibers together while maintaining porosity, then solidifies upon cooling to provide structural support without blocking air flow
3Strength
If the basis weight of the non-woven fabric is increased to strengthen stiffness, then stiffness is improved, but the fabric becomes heavier and more difficult to mount
Solution Approach 1:
The patent changes the bonding mechanism from chemical adhesion to thermal fusion, creating stronger fiber-to-fiber bonds that increase stiffness at lower basis weights, reducing the need to add more material to achieve the required structural rigidity
Solution Approach 2:
The patent creates a composite structure where thermoplastic particles are integrated within the fiber matrix, forming a hybrid material system that combines the mechanical properties of fibers with the bonding properties of thermoplastics to achieve high stiffness at low weight
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 fabric exhibits strong stiffness, high oil absorption, and collection properties, easy processability, and sufficient flame retardancy, making it suitable for filters that require high performance and ease of mounting on range hoods and ventilation fans.
Implementation Method 1
a sheath portion is a low melting point polyester
Implementation Method 2
the composite polyester fiber and the other fibers of the rest are integrated
Implementation Method 3
a core portion is a high melting point polyester having a higher melting point than that of the low melting point polyester
Data Source
AI summary
A non-woven fabric body (11) that forms a non-woven fabric (1) is formed by integrating composite polyester fibers (2) and flame-retardant acrylic fibers (3) which serve as the other fibers of the rest. The composite polyester fibers (2) have a core-sheath structure in which a sheath portion (4) is formed of a low melting point polyester and a core portion (5) is formed of a high melting point polyester having a higher melting point than that of the low melting point polyester. The composite polyester fibers (2) are contained in an amount of 15% to 80% by weight in a total of 100% by weight of the non-woven fabric body (11). Further, an apparent density of the non-woven fabric body (11) ((a basis weight of the non-woven fabric body)/(a thickness of the non-woven fabric body)) is 0.005 g/cm3 to 0.040 g/cm3. In addition, a bending resistance of the non-woven fabric body (11) in a flow direction of the fibers is 50 mN·cm to 220 mN·cm, and a bending resistance in a width direction that is orthogonal to the flow direction is 20 mN·cm to 140 mN·cm.