Synthetic Fiber Filter Medium With Densified Layer for Glass-Free Filtration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing filter media using glass fibers face issues with abrasive wear and potential damage to equipment due to glass fiber shedding, while maintaining high separation efficiency for particles ≥4 µm remains a challenge.
Innovation Solution
A multi-layered filter medium composed of synthetic fibers, including a first layer of natural fibers, a densified second layer of fine fibers produced by meltblown and optionally spunbond processes, and a third layer, which avoids glass fibers and achieves high separation efficiency through controlled pore size distribution and densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass fibers are used in filter media, then separation efficiency for particles ≥4 μm is improved, but equipment damage risk increases due to glass fiber shedding
Solution Approach 1:
The patent removes glass fibers from the filter medium composition entirely, extracting the harmful component while maintaining filtration functionality through alternative materials (cellulose and synthetic fibers). This eliminates the source of glass fiber shedding that causes equipment damage while preserving particle separation capability.
Solution Approach 2:
The invention employs a composite structure combining cellulose fibers with synthetic fibers (polyester, polypropylene, or polyamide) in a multi-layer nonwoven configuration. This composite material approach achieves the required separation efficiency through the synergistic properties of different fiber types without relying on glass fibers, thus avoiding equipment damage while maintaining high filtration performance.
2Manufacturing precision
If glass fiber content is increased to improve separation efficiency, then particle removal performance is improved, but abrasive wear increases
Solution Approach 1:
The patent eliminates glass fibers from the filter medium, removing the abrasive component entirely. The separation efficiency function is transferred to cellulose and synthetic fiber combinations that provide equivalent or superior filtration performance without generating abrasive wear on downstream equipment.
Solution Approach 2:
The invention changes the material composition parameters by replacing glass fibers with cellulose and synthetic fibers having different physical properties. This parameter change maintains the pore structure and filtration characteristics needed for high particle removal efficiency while eliminating the abrasive nature of glass fibers.
3Object-affected harmful factors
If synthetic fibers are used instead of glass fibers, then equipment damage is prevented, but separation efficiency may be compromised
Solution Approach 1:
The patent creates a composite nonwoven structure combining cellulose fibers with synthetic fibers (polyester, polypropylene, or polyamide). This composite achieves ≥99.3% separation efficiency for particles ≥4 μm through the synergistic properties of the fiber combination, matching or exceeding glass fiber performance while eliminating equipment damage risks.
Solution Approach 2:
The invention optimizes the local properties of different fiber components within the nonwoven structure. Cellulose provides structural integrity and porosity control, while synthetic fibers contribute to pore formation and filtration efficiency. This local quality differentiation within the composite enables high separation efficiency without relying on abrasive glass fibers.
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 filter medium achieves ≥99.3% initial efficiency for particles ≥4 µm without glass fibers, preventing equipment damage and maintaining effective filtration performance.
Implementation Method 1
a second layer which is positioned between the first layer and the third layer and comprises a plurality of fibers formed by a melt-blown process
Data Source
AI summary
The present invention relates to a multi-layered filter medium with a densified layer made of synthetic fibers, as well as to the use and the method for its production.