Vacuum Cleaner Filter Bag Structure for Higher Dust Storage
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Solution Overview
Problem
Existing filter bags for vacuum cleaners have insufficient dust storage capacity due to high bulk density, which limits their ability to effectively collect dust despite advancements in multi-layer structures and nonwoven materials.
Innovation Solution
A filter bag with a structure comprising at least three layers, including a fleece layer and a fiber fleece layer connected by a minimal number of welded joints, achieving a low bulk density and high porosity to enhance dust storage capacity, with an average of no more than 10 welded joints per 10 cm² and a porosity of at least 65%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-layer filter bag structure is used to improve dust collection, then dust separation ability is improved, but bulk density increases and dust storage capacity is reduced
Solution Approach 1:
The filter bag is divided into multiple functional layers (coarse dust filter layer with fibrillated fibers, fine dust filter layer with electrostatically charged nonwoven fabric, and support layer) to achieve both effective dust separation and high dust storage capacity. Each layer performs a specific function, allowing the system to maintain low bulk density while providing comprehensive filtration.
2Strength
If ultrasonic welding is used to connect nonwoven layers, then structural strength is improved, but the number of welded joints increases and bulkiness is reduced
Solution Approach 1:
Ultrasonic welding is applied selectively at specific locations where structural strength is most needed, rather than using continuous welding across the entire filter bag surface. This localized approach maintains necessary structural integrity while preserving the bulkiness and low bulk density of the nonwoven layers.
Solution Approach 2:
Instead of welding all layers extensively, the invention uses a limited number of welded joints only where structurally necessary, allowing the majority of the filter bag to maintain its natural bulky structure and high dust storage capacity.
3Stability of the object's composition
If the number of welded joints is increased to improve layer connection, then structural integrity is improved, but porosity decreases and dust storage capacity is reduced
Solution Approach 1:
Welded joints are concentrated at specific critical locations where structural integrity is most important, while the majority of the filter bag surface remains unwelded to maintain high porosity and dust storage capacity.
Solution Approach 2:
The invention uses porous nonwoven materials with controlled fiber diameter distributions that maintain high porosity even with minimal welding, allowing the filter bag to store more dust while remaining structurally sound at the welded locations.
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 reduced bulk density and increased porosity result in a significantly higher dust storage capacity, with the filter bag being 15 to 42% thicker than comparative materials, effectively addressing the limitations of prior art in dust collection.
Implementation Method 1
at least two layers, which consist of at least one fleece layer and at least one fiber fleece layer, being connected by welded joints
Data Source
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AI summary
The invention relates to a filter bag for a vacuum cleaner, comprising at least three layers, whereby at least two layers, consisting of at least one non-woven fabric layer and one non-woven fibre layer, are connected together by a weld. A high degree of fluffiness is obtained due to the low number of welds per surface. The invention also relates to the use of said type of filter bag.