Composite Vacuum Filter Bag for Dust Storage and Low Pressure Loss
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Solution Overview
Problem
Existing filter bags, particularly those using nonwoven composite materials, suffer from inadequate dust storage capacity and insufficient filtration efficiency across varying particle sizes, leading to suboptimal performance in vacuum cleaners.
Innovation Solution
A filter bag comprising at least three layers, with two layers being a nonwoven fabric layer and one nonwoven fibre layer connected by welds, where the nonwoven fibre layer contains uncharged staple fibres or filaments, and the weld pattern covers no more than 5% of the surface area, with an average of at least 20 welds per 10 cm², enhancing dust storage capacity and filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nonwoven composite materials are used in filter bags, then production costs are reduced and uniformity is improved, but dust storage capacity becomes inadequate
Solution Approach 1:
The filter bag uses a composite material consisting of multiple nonwoven layers with different properties: a first nonwoven layer (5-50 g/m²) for initial filtration, a second nonwoven layer (30-200 g/m²) for structural support, and an optional third nonwoven layer (20-300 g/m²) for enhanced dust storage. This multi-layer composite structure resolves the contradiction by combining materials with different characteristics to achieve both cost-effectiveness and adequate dust storage capacity.
2Ease of manufacture
If electrostatically charged split fibres are connected by ultrasonic welding, then production costs are reduced and uniformity is improved, but dust storage capacity remains insufficient
Solution Approach 1:
The patent combines ultrasonic-welded nonwoven layers with different basis weights and structures to create a composite filter medium. The first layer (5-50 g/m²) provides fine filtration, the second layer (30-200 g/m²) provides structural integrity and dust storage, and the optional third layer (20-300 g/m²) enhances dust storage capacity. This composite approach maintains the cost benefits of ultrasonic welding while achieving adequate dust storage through layered architecture.
Solution Approach 2:
The filter medium is segmented into multiple functional layers, each with specific basis weight ranges and properties. The first layer (5-50 g/m²) handles initial particle capture, the second layer (30-200 g/m²) provides structural support and intermediate dust storage, and the third layer (20-300 g/m²) when present, provides additional dust storage capacity. This segmentation allows each layer to optimize its function while collectively achieving both cost-effectiveness and adequate dust storage.
3Stability of the object's composition
If weld points are increased to stabilize the filter medium, then structural stability is improved, but pressure loss increases
Solution Approach 1:
The patent applies ultrasonic welding at specific locations to create a pattern of weld points that provides structural stability only where needed. The weld points are distributed across the filter medium at controlled density, creating localized bonding zones that maintain structural integrity while leaving large portions of the filter material unwelded to preserve airflow characteristics and minimize pressure loss.
Solution Approach 2:
Instead of welding the entire filter medium surface, the patent uses partial welding with weld points covering only a portion of the total surface area. This partial action provides sufficient structural stability for filter bag handling and installation while maintaining adequate open area for air flow, thereby minimizing pressure loss. The weld point density is optimized to provide just enough stability without excessive bonding that would restrict airflow.
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 proposed filter bag design achieves a significantly higher dust storage capacity with minimal pressure loss, ensuring effective filtration across a range of particle sizes while maintaining low production costs and improved uniformity.
Implementation Method 1
at least one nonwoven fabric layer and at least one nonwoven fibre layer being connected by a weld
Implementation Method 2
a filter bag for a vacuum cleaner made of a composite material... has a significantly higher dust storage capacity
Data Source
AI summary
A filter bag for a vacuum cleaner made of a composite material including at least three layers, at least two layers which include a nonwoven fabric layer and at least one nonwoven fiber layer being connected by a weld.