Wet-Laid Nonwoven Filter Media for Uniform Pore Filtration
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Solution Overview
Problem
Conventional wet type nonwoven fabrics used as filters face issues with nonuniform pore diameters and insufficient collection efficiency due to nonuniform fiber lengths and diameters, leading to poor filter quality.
Innovation Solution
A wet type nonwoven fabric comprising short fibers with a specific diameter range and aspect ratio, combined with a binder fiber, is developed. The short fibers are formed by cutting conjugate fibers with an island and sea component, and the binder fibers are unstretched polyester fibers, ensuring uniform pore diameters and improved fiber dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional wet type nonwoven fabric including polyester fiber is used as a filter, then the fabric can be manufactured with conventional materials, but the pore diameter on the surface is nonuniform resulting in insufficient collection efficiency
Solution Approach 1:
The invention changes the fiber diameter parameter to 550-800 nm (ultrafine range) and controls the L/D ratio within 100-2500 to achieve uniform pore diameters on the fabric surface, directly resolving the pore uniformity issue that limits collection efficiency
Solution Approach 2:
The invention uses a composite structure of ultrafine short fiber A (filtering function) and binder fiber B (structural support function) with specific fineness control, creating a composite material system that achieves both uniform pore structure and high collection efficiency
2Manufacturing precision
If wet type nonwoven fabric including micro glass or synthetic pulp is used as a filter, then the fabric can be manufactured with these materials, but the fiber length and fiber diameter are nonuniform resulting in insufficient filter quality
Solution Approach 1:
The invention specifies ultrafine fiber diameter of 550-800 nm and controls the L/D ratio within 100-2500, creating uniform fiber dimensions that produce consistent pore structures and high-quality filters, eliminating the nonuniformity problems of conventional materials
Solution Approach 2:
The invention achieves homogeneity in fiber properties by using ultrafine short fibers with controlled L/D ratios and specific fineness, ensuring uniform distribution and consistent filtering performance across the entire filter surface
3Reliability
If short fiber with small fineness is used to improve collection efficiency, then the filter performance is enhanced, but the fiber is difficult to handle and process
Solution Approach 1:
The invention optimizes the L/D ratio to 100-2500 and fiber diameter to 550-800 nm, creating ultrafine short fibers that are easy to disperse and process while maintaining high collection efficiency, resolving the handling difficulty of ultrafine fibers
Solution Approach 2:
The invention applies different fiber properties at different locations: ultrafine short fiber A (550-800 nm) for filtering performance and binder fiber B with specific fineness for structural integrity, optimizing both performance and manufacturability
Data Source
Figure 1~2
AI summary
The present invention is a wet type nonwoven fabric that includes two or more kinds of fibers, wherein the wet type nonwoven fabric includes a short fiber A that is constituted of a fiber-forming thermoplastic polymer and has a fiber diameter D of from 100 to 1000 nm and the ratio of a fiber length L to the fiber diameter D, L/D, in the range of from 100 to 2500 in from 4 to 50% by weight relative to the total weight of the nonwoven fabric, and a binder fiber B that has a single fiber fineness of 0.1 dtex or less in from 10 to 50% by weight relative to the total weight of the nonwoven fabric.