Pleated Filter Medium with Spacer Embossings
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Solution Overview
Problem
Existing air filters face challenges in achieving a balance between high filtration efficiency and long service life while maintaining low pressure differential, which is crucial for energy-efficient vehicle and ventilation systems, especially in electric vehicles and buildings with stringent energy standards.
Innovation Solution
A semi-finished product for air filters featuring a nonwoven fibrous structure produced in a melt-spinning process, with pleated layers and embossings configured as spacers and fold edges, joined without adhesives by fibers, to enhance rigidity, stability, and filtration efficiency while minimizing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filter medium is pleated to increase surface area, then filtration efficiency is improved, but the pressure differential increases
Solution Approach 1:
The patent transitions from traditional 2D flat filter media to 3D pleated structures with controlled fold spacing. By creating folds with specific spacing (10-30mm) and using spacers to maintain fold separation, the filter medium gains volumetric dimensionality while preserving large active filtration surfaces, thereby improving filtration efficiency without proportionally increasing pressure differential
Solution Approach 2:
The patent applies different structural qualities to different regions of the filter medium. Spacers are strategically placed at fold edges to maintain separation only where needed, while the filter media between spacers maintains close proximity for effective filtration. This localized application of spacing preserves surface area while minimizing pressure loss
2Stability of the object's composition
If adhesive bonding is used to join pleated layers, then structural stability is improved, but the active filtration area is reduced
Solution Approach 1:
The patent replaces solid adhesive bonds with porous wire spacers that maintain structural stability while allowing air flow through the filter medium. The wire spacers create open structures that do not block filtration paths, preserving active filtration area while providing mechanical support to maintain pleated configuration
Solution Approach 2:
The patent introduces wire spacers as intermediary elements between pleated layers instead of using direct adhesive bonding. These spacers act as mediators that provide structural support and maintain fold spacing without creating solid barriers that would reduce filtration area, allowing air to pass through the filter medium unimpeded
3Reliability
If fold spacing is reduced to increase filtration surface, then filtration efficiency is improved, but fold stability deteriorates
Solution Approach 1:
The patent optimizes the fold spacing parameter to a specific range (10-30mm) that balances filtration surface area with fold stability. This parameter optimization, combined with spacer placement, ensures that folds remain stable and open during operation while maintaining sufficient surface area for effective filtration of particles including MPPS
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 solution increases the service life of filters, reduces pressure drop, and enhances filtration efficiency by maintaining the filter medium's structure integrity and active filtration area, thereby improving energy efficiency and comfort in vehicles and buildings.
Implementation Method 1
The filter medium has a zigzag folding; i.e. pleating, in order to increase the surface of the filter medium per filter surface unit of measure
Implementation Method 2
respective first adjacent layers exhibit at least one first embossing configured as a spacer between the at least two first adjacent layers
Implementation Method 3
At least one pair of first embossings of the at least one first adjacent layers are in contact so as to form a spacer
Data Source
Figure 1~2a
Figure 2b
Figure 3
AI summary
The inventive semi-finished product for a filter, particularly an air filter, comprises a filter medium, wherein said filter medium comprises a nonwoven having fibrous structure produced in a melt-spinning process and at least partially arranged in pleated layers.