Thin Filtering Medium for Mini-Pleats Processing
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Solution Overview
Problem
Existing air cleaner filters face challenges in integrating dust collection and deodorization functions while maintaining low pressure drop and high air volume treatment, especially when subjected to mini-pleats processing, due to issues with fiber thickness, airflow resistance, and structure pressure drop.
Innovation Solution
A filtering medium composed of a non-woven fabric with non-crimped single fibers having a high Young's modulus and fineness, combined with a gas adsorbing substance like active carbon, adhered to the fabric with a water-soluble resin, achieving a specific strength at 1% elongation of 150 N·cm/g or more and an apparent density of 0.3 g/cm³ or less, allowing for mini-pleats processing without significant structure pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the dust collecting portion and deodorizing portion are integrated into a single filtering medium, then washing simplicity and filter exchange ease are improved, but the thickness of the filtering medium increases and the treatment air volume decreases
Solution Approach 1:
The patent integrates the dust collecting portion (HEPA filtering medium) and deodorizing portion (adsorbent layer) into a single filtering medium structure. The HEPA filtering medium serves as the base layer for dust collection, while the adsorbent layer is formed on its surface for deodorization. This merging allows the filter to perform both functions simultaneously and enables single-step washing and reuse, resolving the contradiction between operational simplicity and functional integration.
2Productivity
If mini-pleats processing is applied to increase the filtering medium area, then the treatment air volume capability is improved, but the structure pressure drop increases
Solution Approach 1:
The patent applies mini-pleats processing to the filtering medium, transforming a two-dimensional flat structure into a three-dimensional pleated structure. This dimensional change increases the effective filtering area within the same footprint, enabling larger treatment air volume capability. The pleats are designed with controlled dimensions (pleat height of 2-5mm, pleat width of 3-6mm) to maximize area while managing pressure drop characteristics.
Solution Approach 2:
The patent optimizes the physical parameters of the filtering medium including basis weight (30-80g/m²), thickness (0.3-1.0mm), and apparent density (0.05-0.3g/cm³) to achieve low pressure drop. The adsorbent layer is controlled at 5-50g/m² to maintain porosity and airflow characteristics. These parameter changes enable the filtering medium to accommodate mini-pleats while maintaining low structure pressure drop.
3Adaptability or versatility
If a thick filtering medium is used to accommodate both dust collection and deodorization functions, then the deodorization capability is improved, but the filtering medium area that can be accommodated in the unit decreases
Solution Approach 1:
The patent employs a thin filtering medium structure with total thickness of 0.3-1.0mm, utilizing thin film technology to accommodate both dust collection and deodorization functions. The HEPA filtering medium (0.1-0.5mm) serves as the thin base layer, and the adsorbent layer (0.05-0.2mm) is applied as a surface coating. This thin-film approach provides sufficient deodorization capability while maximizing the filtering medium area that can be accommodated in the filter unit.
Solution Approach 2:
The patent uses porous materials for both the HEPA filtering medium and the adsorbent layer to maintain high air permeability. The porous structure allows air to flow through efficiently while providing sufficient surface area for deodorization. The porosity is controlled to ensure low pressure drop across the thin filtering medium, enabling both deodorization function and large filtering area within the same unit.
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 enables a filtering medium with high air permeability, effective deodorization, and dust collection, maintaining low pressure drop even under mini-pleats processing, facilitating easy washing and reuse, and reducing unit pressure drop, thus enhancing the efficiency and longevity of the filter unit.
Implementation Method 1
a gas adsorbing substance which includes a porous material and has a particle diameter of 40 μm or less adhered to the nonwoven fabric sheet
Data Source
AI summary
By providing a thin-type deodorizing filtering medium which can be mini-pleats-processed, a washing-regenerable filtering medium in which the deodorizing filtering medium and a dust collecting filtering medium are integrated and, further, a low pressure drop / dust collecting deodorizing filter unit which can be subjected to large air volume treatment are provided. A non-crimped single fiber having a specified Young's modulus and a specified fineness is used to prepare a nonwoven fabric sheet having high stiffness, and a gas adsorbing substance is adhered and fixed thereto.