Waved Filter Media for Sustained Filtration Efficiency
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Solution Overview
Problem
Current filtration media, especially those electrostatically charged, experience a significant decrease in alpha value when the electrostatic charge is removed, leading to reduced filtration efficiency and capacity, necessitating the development of improved filter media with sustained high alpha values.
Innovation Solution
A filter media with a fine fiber filtration layer and a coarse support layer in a waved configuration, where the coarse support layer has varying density and the fine fiber layer has a significantly increased surface area, maintaining separation of peaks and troughs to enhance filtration efficiency and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrostatically charged synthetic filtration media are used to achieve high alpha values, then filtration efficiency is improved, but the alpha value significantly decreases when the electrostatic charge is removed
Solution Approach 1:
The patent changes the physical structure parameter of the filtration media from planar to waved configuration, increasing the surface area and creating a three-dimensional filtration structure that maintains high alpha values without relying on electrostatic charge
Solution Approach 2:
The patent uses composite material construction with multiple layers including fine fiber filtration layers and coarse support layers, where each layer serves a specific function to achieve sustained high filtration efficiency
2Ease of manufacture
If planar filter media configuration is used, then manufacturing is simpler, but the surface area and filtration capacity are limited
Solution Approach 1:
The patent transitions from two-dimensional planar filter media to three-dimensional waved filter media, creating peaks and troughs that significantly increase the effective surface area and filtration capacity while maintaining manufacturability through conventional web formation processes
3Reliability
If fine fiber filtration layer is used to increase surface area, then filtration efficiency is improved, but the structural stability and support become challenging
Solution Approach 1:
The patent segments the filter media into distinct functional layers: fine fiber filtration layers for high-efficiency particle capture and coarse support layers for structural stability, with each layer optimized for its specific function
Solution Approach 2:
The patent combines fine fibers and coarse fibers in a layered composite structure where the fine fiber layer provides filtration efficiency and the coarse support layer provides mechanical strength and structural integrity
Data Source
AI summary
Various high performance, high efficiency filter media are provided that are cost effective and easy to manufacture. In particular, various filter media are provided having at least one layer with a waved configuration that results in an increased surface area, thereby enhancing various properties of the filter media. The filter media can be used to form a variety of filter elements for use in various applications.