Single-Layer Vacuum Cleaner Filter Bag With Calendered Microfiber Nonwoven
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Solution Overview
Problem
Existing vacuum cleaner filter bags require multiple layers of nonwoven materials to achieve sufficient separation performance and mechanical strength, making them costly to produce due to the need for various production processes and layer connections.
Innovation Solution
A single-layer vacuum cleaner filter bag with a melt-spun microfiber nonwoven layer, which is thermally or ultrasonically calendered to create a self-supporting fabric with sufficient strength and separation performance, eliminating the need for multiple layers and associated production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of nonwoven material are used to achieve sufficient separation performance and mechanical strength, then the filter bag has adequate performance, but the production cost increases due to multiple production processes and layer connections
Solution Approach 1:
The patent combines multiple functions (separation, mechanical strength, self-support) into a single nonwoven layer with optimized properties, eliminating the need for multiple layers and their connections. This merging approach reduces production complexity and cost while maintaining required performance.
Solution Approach 2:
The patent uses a composite nonwoven structure combining different fiber types (cellulose fibers for separation, synthetic fibers for strength) within a single layer, achieving both separation performance and mechanical strength without requiring multiple separate layers.
2Reliability
If multiple layers of nonwoven material are used, then sufficient separation performance is achieved, but the device complexity increases due to multiple production processes and connection requirements
Solution Approach 1:
The patent merges multiple functional layers into a single integrated nonwoven layer, eliminating the need for separate production processes and connection steps. This simplifies the production process while maintaining separation performance through optimized fiber composition and structure.
3Ease of manufacture
If a single nonwoven layer is used, then production cost is reduced, but the mechanical strength and self-support capability may be insufficient
Solution Approach 1:
The patent employs a composite nonwoven material containing both natural fibers (cellulose) for separation and synthetic fibers (polyester, polypropylene, or polyacrylonitrile) for mechanical strength. This composite structure provides sufficient self-support capability in a single layer.
Solution Approach 2:
The patent optimizes parameters such as fiber diameter distribution (0.1-10 μm), basis weight (50-200 g/m²), and fiber composition ratios to achieve the required mechanical strength and self-support capability in a single nonwoven layer.
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 single-layer design reduces production costs while maintaining effective separation performance and mechanical strength, making it suitable for cost-effective manufacturing and short-term use applications.
Implementation Method 1
The nonwoven layer is a calendered nonwoven, in particular a thermally or ultrasonically calendered nonwoven. For thermal calendering, the initially unconsolidated fleece can be passed between two rollers, at least one of which is heated to the melting temperature of the fibers forming the fleece.
Implementation Method 2
The nonwoven layer is a calendered nonwoven, in particular a thermally or ultrasonically calendered nonwoven. Ultrasonic calendering or ultrasonic strengthening is based on the conversion of electrical energy into mechanical vibration energy.
Implementation Method 3
The applicants of the present invention have found that it is possible to produce a vacuum cleaner filter bag with exactly one nonwoven layer in the form of a melt-spun microfiber nonwoven layer, i.e. a nonwoven layer made of melt-spun microfiber nonwoven fabric, which has sufficient separation performance.
Data Source
Figure 1~2
Figure 3
AI summary
The invention comprises a vacuum cleaner filter bag with a bag wall, wherein the bag wall comprises exactly one nonwoven layer in the form of a melt-spun microfiber nonwoven layer.