Composite nonwoven filter media with hierarchically arranged fibres of different geometries for automotive engine intake air filtration

This paper reports the development, characterization, and performance assessment of a series of promisingly designed nonwoven air filter media for automotive engine intake application. Commercially available fibres are processed through a laboratory-based needle-punched nonwoven line to prepare a plurality of composite nonwoven filter media with hierarchically arranged fibres of different sizes or shapes. The filter media are then assessed for their dynamic filtration performance both at cleaned and clogging states by employing testing devices based on gravimetric measurement and particle counting technologies. The composite nonwoven filter media with hierarchically arranged fibres of different geometries display excellent filtration performance and are found to be very promising for commercial engine application. As compared to their homogeneously-mixed counterparts, the composite nonwoven filter media offer higher gravimetric as well as fractional filtration efficiency, higher dust holding capacity, and more delayed rise of pressure drop.