Silicone Wax Additive Filter Media Pleat Stability
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Solution Overview
Problem
Conventional fibrous nonwoven air filters, especially those with electret-based designs, face inefficiencies due to rapid charge masking by particles and the need for costly metal wires for pleating, leading to misleading initial efficiency ratings and increased costs.
Innovation Solution
Incorporating silicone or wax additives into fibrous nonwoven filter media composed of glass, polymer, and cellulosic fibers, along with a binder, to enhance filtration efficiency and eliminate the need for metal wires by forming self-supporting pleats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electret-based filters are used to achieve good initial efficiency ratings, then filtration efficiency is improved, but the efficiency rapidly drops due to charge masking by particles
Solution Approach 1:
The patent changes the chemical composition parameters of the filter media by incorporating silicone or wax additives into the fiber structure. These additives modify the surface properties of the fibers, enabling them to maintain filtration efficiency over time without relying on electret charges that get masked by particles. The silicone or wax additives create a more stable filtration mechanism that resists charge masking.
2Stability of the object's composition
If metal wires are used to permanently fold the media for pleating, then the filter structure is stabilized, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the metal wire component from the filter construction by using silicone or wax additives to provide the necessary structural support for pleating. These additives create self-supporting pleats that function without requiring external metal wire reinforcement, thereby removing the costly metal wire component while maintaining pleat stability.
Solution Approach 2:
The patent replaces expensive metal wires with inexpensive silicone or wax additives that can be applied during the manufacturing process. These additives serve as temporary or permanent structural supports without requiring costly metal components, reducing manufacturing costs while achieving the desired pleat stability.
3Reliability
If lower density fibers are used to increase surface area for better efficiency, then filtration performance is improved, but the filter requires metal wires for support
Solution Approach 1:
The patent changes the physical and chemical parameters of the filter media by incorporating silicone or wax additives that modify the fiber properties. These additives enhance the structural integrity of lower density fibers, allowing them to support themselves without metal wire reinforcement while maintaining the high surface area needed for efficient filtration.
Data Source
AI summary
A method of improving filtration efficiency of a fibrous nonwoven filter media comprises providing a filter media and incorporating in the filter media one or more additives selected from the group consisting of silicone additives, wax additives, and mixtures thereof. The filter media comprises glass fibers, polymer fibers, and optionally binder. Inclusion of silicone and/or wax additive(s) in a filter media has surprisingly been found to increase filtration efficiency, for example, by 10-15%.