Pleated PTFE Filter Medium With Embossed Locks for Low Pressure Loss
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Solution Overview
Problem
Conventional air filter units with porous PTFE films experience increased pressure loss due to clogging from dust, leading to weight gain and reduced filtration efficiency when using separators or spacers to maintain a zigzag shape.
Innovation Solution
A filter medium with a porous PTFE film and embossed projections is used, maintaining the zigzag shape without increasing weight, by allowing embossed projections to lock and stabilize the filter medium, thereby reducing pressure loss and maintaining dust collection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a separator or spacer is inserted into the concave part of a filter medium to maintain a zigzag shape, then the shape stability is improved, but the weight of the air filter unit increases and the effective filtration area decreases
Solution Approach 1:
The invention extracts and removes the separator or spacer components from the filter medium structure. Instead of inserting additional elements to maintain the zigzag shape, the patent uses the filter medium itself (porous PTFE film) to form and maintain the zigzag configuration through its inherent flexibility and structural design, thereby eliminating the need for separate support components that would increase weight.
Solution Approach 2:
The invention merges the shape-maintaining function with the filtration function by making the filter medium itself capable of maintaining the zigzag shape without requiring separate separator or spacer components. The porous PTFE film is designed to inherently maintain its folded configuration while performing dust collection, combining multiple functions into a single integrated structure.
2Stability of the object's composition
If a separator or spacer is inserted into the concave part of a filter medium to maintain a zigzag shape, then the shape stability is improved, but the effective filtration area becomes smaller causing pressure loss to increase
Solution Approach 1:
The invention extracts and removes the separator or spacer components that would occupy space within the filter medium structure. By eliminating these non-filtration elements, the entire surface area of the filter medium remains available for dust collection, maximizing the effective filtration area and minimizing pressure loss while maintaining shape stability through the filter medium's own structural design.
Solution Approach 2:
The invention merges the shape-maintaining function with the filtration function by making the filter medium itself capable of maintaining the zigzag shape without requiring separate separator or spacer components. The porous PTFE film is designed to inherently maintain its folded configuration while performing dust collection, combining multiple functions into a single integrated structure.
3Reliability
If the porous PTFE film is used as a filter medium, then dust collection efficiency is improved, but clogging occurs frequently leading to rapid pressure loss increase
Solution Approach 1:
The invention applies local quality by creating a gradient or variation in the filter medium structure, where different regions of the porous PTFE film have different properties. This allows the filter to handle dust loading more effectively in high-concentration areas while maintaining breathability in other regions, preventing uniform clogging and extending service life while preserving high dust collection efficiency.
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 effectively suppresses pressure loss in air filter units while maintaining dust collection efficiency comparable to conventional filters, without increasing the weight or reducing the effective filtration area.
Implementation Method 1
a porous film (which will be hereinafter referred to as a porous PTFE film) made of polytetrafluoroethylene (which will be hereinafter referred to as PTFE) is used as a dust collecting filter
Data Source
AI summary
A filter medium for an air filter collecting dust in an air flow has a principal collection layer including a porous polytetrafluoroethylene film. A surface of the filter medium is provided with a plurality of embossed projections. Preferably, a processed filter medium maintains a zigzag shape by pleating an unprocessed filter medium to create mountain folds and valley folds. Preferably, an air filter unit includes such a processed filter medium and a frame body holding the processed filter medium.