Abstract
To satisfy the requirements of channel-type ultra-low penetration air (ULPA) filters for high filtration efficiency, low pressure drop, and good corrugation processability, a three-layer composite filter medium with a bast-fiber surface layer/glass wool–lyocell blended core layer/bast-fiber surface layer structure was designed and prepared. The effects of surface-layer material, core-layer fiber composition, surface-layer basis weight, and processing conditions on the overall performance of the medium were systematically investigated. Bast-fiber paper exhibited the best corrugation processability and mechanical performance and was selected as the surface layer. The optimal core-layer composition was 25 wt.% 475-79 glass wool fibers, 30 wt.% 475-59 glass wool fibers, and 45 wt.% lyocell fibers, yielding an original-sheet filtration efficiency of 99.9996% and a pressure drop of 381 Pa. Further optimization showed that a bast-fiber surface layer with a basis weight of 15 g/m2 provided the best balance among pleat retention, structural stability, and low-resistance characteristics. Under optimized corrugation conditions of 120 °C roller temperature, 10 m/min roller speed, and 0.480 mm roller gap, a desirable pleat morphology suitable for channel-type structures was obtained. The resulting channel-type ULPA filter maintained a filtration efficiency of 99.99954%, while increasing the effective filtration area by 51.6% and reducing the pressure drop by 26.1% compared with a conventional pleated filter with the same dimensions. These results provide a useful reference for the design and application of low-resistance, high-efficiency filter media for channel-type ULPA filters.