Nonwoven Filter Media Composition for Dust Holding and Strength
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Solution Overview
Problem
Existing filter media exhibit issues such as low dust holding capacity, low filtration efficiency, poor mechanical strength, and fiber shedding, which affect their performance in removing contaminants from fluids.
Innovation Solution
A filter media comprising a non-woven fiber web made of fibrillated fibers, glass fibers, and binder fibers, where the fibrillated fibers have an average Canadian Standard Freeness value of greater than or equal to 105 mL, and glass fibers are present in an amount greater than 20 wt%, enhancing properties like air permeability, dust holding capacity, and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter media are used, then manufacturing is simple, but filtration efficiency and dust holding capacity are low
Solution Approach 1:
The filter media combines three distinct fiber types (fibrillated fibers, glass fibers, and binder fibers) into a composite nonwoven structure. Each fiber type contributes specific properties: fibrillated fibers provide dust holding capacity through their split-fiber morphology, glass fibers enhance filtration efficiency with their uniform fine diameter, and binder fibers provide mechanical strength. This composite approach resolves the contradiction by achieving high filtration efficiency through material composition rather than structural complexity.
Solution Approach 2:
The patent applies local quality by assigning different functions to different fiber types within the same media structure. Fibrillated fibers are positioned to maximize surface area for particle capture, glass fibers are distributed to provide consistent filtration zones, and binder fibers are placed to reinforce mechanical weak points. This functional differentiation within the composite structure achieves high filtration efficiency without requiring complex overall design.
2Reliability
If filter media with high filtration efficiency is used, then dust holding capacity improves, but mechanical strength decreases
Solution Approach 1:
The composite structure explicitly addresses this contradiction by incorporating binder fibers designed to provide mechanical strength while maintaining high dust holding capacity. The binder fibers form a structural framework that supports the fibrillated and glass fibers, preventing media collapse under pressure differentials while preserving the high-surface-area fiber networks needed for particle capture.
Solution Approach 2:
Different regions of the media perform different functions: the fibrillated and glass fiber zones are optimized for particle capture and filtration, while the binder fiber network provides mechanical reinforcement throughout the structure. This spatial and functional differentiation allows the media to simultaneously achieve high dust holding capacity and adequate mechanical strength.
3Reliability
If more glass fibers are added to improve filtration efficiency, then cleanliness improves, but manufacturing complexity increases
Solution Approach 1:
The patent specifies precise parameter ranges to balance cleanliness with manufacturing ease: glass fibers constitute 20-60 wt% of the total fiber content, with an average diameter of 0.5-5 micrometers. These parameter specifications provide clear manufacturing guidelines that achieve the desired cleanliness level (reduced fiber shedding) while maintaining practical manufacturability through standardized fiber procurement and processing parameters.
Data Source
AI summary
Filter media comprising non-woven fiber webs having one or more advantageous physical properties are generally described. In some embodiments, a filter media and/or non-woven fiber web described herein comprises a combination of fibers that results in enhanced physical properties. For example, the non-woven fiber web may comprise a combination of fiber types that is advantageous, such as a combination comprising fibrillated fibers, glass fibers, and/or binder fibers. In some cases, the filter media and/or non-woven fiber web comprising the combination of fibers may be formed into undulations (e.g., by a creping and/or microcreping process) to further enhance the physical properties of the filter media and/or non-woven fiber.