V-shaped pleated high-efficiency filters (commonly referred to as “V-shaped HEPA filters”; HEPA stands for High-Efficiency Particulate Air) are widely used in clean Spaces of new energy factories (such as lithium battery, photovoltaic, hydrogen fuel cell and other production bases) due to their core advantages of high filtration efficiency, large dust holding capacity, low resistance and compact design. It is a key purification device for ensuring the cleanliness of the production environment and improving the yield of products. The following is a detailed explanation from five dimensions: application background, core value, specific application scenarios, key points of selection and maintenance, and technical trends.
I. Application Background: The strict requirements for clean Spaces in new energy production
The production process of new energy products (especially lithium batteries and photovoltaic modules) is extremely sensitive to particles (dust, metal impurities), microorganisms, humidity, static electricity, etc. in the environment. Even the slightest pollution may directly lead to product failure or performance degradation.
In the core processes of lithium batteries such as electrode coating, rolling, stacking/winding, and liquid injection, if there are micron-sized dust or metal particles in the environment, it may cause short circuits in the electrode, battery bulging, and even fire risks.
During the processes of silicon wafer cutting, cleaning, coating and solar cell welding in photovoltaic modules, particulate contamination can lead to uneven coating and hidden cracks in the solar cells, directly reducing the conversion efficiency.
Hydrogen fuel cells: During the preparation of membrane electrodes (abbreviated as MEAs, which stands for Membrane Electrode Assemblies) and the processing of bipolar plates, impurities can clog the gas diffusion layer, affecting the proton conduction efficiency.
According to national standards (such as GB 50472-2018 “Code for Design of Clean Rooms in Electronic Industry”; GB stands for Guobiao, meaning “national standard” in China), the core production area of new energy usually requires a cleanliness level of Class 100 to Class 10000 (ISO 5 to 7 grades), and the V-shaped pleated high-efficiency filter is precisely the “terminal barrier” to achieve this cleanliness level.
Ii. Core Value of V-shaped Pleated High-Efficiency Filters: Unique advantages for Adapting to new energy factories
Compared with traditional flat-plate high-efficiency filters, the V-shaped structure design makes it more suitable for the purification requirements of large Spaces, high air volume and heavy load in new energy factories. Its core advantages can be summarized as “four highs and two lows”
The production process of new energy products (especially lithium batteries and photovoltaic modules) is extremely sensitive to particles (dust, metal impurities), microorganisms, humidity, static electricity, etc. in the environment. Even the slightest pollution may directly lead to product failure or performance degradation.
In the core processes of lithium batteries such as electrode coating, rolling, stacking/winding, and liquid injection, if there are micron-sized dust or metal particles in the environment, it may cause short circuits in the electrode, battery bulging, and even fire risks.
During the processes of silicon wafer cutting, cleaning, coating and solar cell welding in photovoltaic modules, particulate contamination can lead to uneven coating and hidden cracks in the solar cells, directly reducing the conversion efficiency.
Hydrogen fuel cells: During the preparation of membrane electrodes (abbreviated as MEAs, which stands for Membrane Electrode Assemblies) and the processing of bipolar plates, impurities can clog the gas diffusion layer, affecting the proton conduction efficiency.
According to national standards (such as GB 50472-2018 “Code for Design of Clean Rooms in Electronic Industry”; GB stands for Guobiao, meaning “national standard” in China), the core production area of new energy usually requires a cleanliness level of Class 100 to Class 10000 (ISO 5 to 7 grades), and the V-shaped pleated high-efficiency filter is precisely the “terminal barrier” to achieve this cleanliness level.
Ii. Core Value of V-shaped Pleated High-Efficiency Filters: Unique advantages for Adapting to new energy factories
Compared with traditional flat-plate high-efficiency filters, the V-shaped structure design makes it more suitable for the purification requirements of large Spaces, high air volume and heavy load in new energy factories. Its core advantages can be summarized as “four highs and two lows”
| Advantage dimension | Specific manifestations | The value for new energy factories |
| High filtration efficiency |
The filtration efficiency reaches HEPA level (≥99.97%@0.3μm) or ULPA level (≥99.999%@0.12μm), capable of capturing fine dust and metal particles. |
Directly intercept the pollutants generated during the production process to meet the cleanliness requirements of core procedures and reduce the product scrap rate. |
|
High dust holding capacity |
The pleat density is high (the number of pleats in a single filter element can reach hundreds), and the filtration area is 3 to 5 times that of the flat plate type of the same size, with the dust holding capacity increased by 2 to 3 times. | Reduce the frequency of filter replacement and lower the downtime for maintenance (most new energy factories operate continuously, resulting in extremely high downtime costs). |
| High air volume compatibility | The rated air volume of a single unit can reach 1000 to 2000 m³/h, and multiple units can be combined to meet the air flow organization requirements of “high air volume and low air velocity” in clean rooms. | It is suitable for the ventilation and purification requirements of large-scale clean workshops in new energy factories (such as lithium battery coating workshops with an area often exceeding 1,000 square meters). |
|
Baja resistencia |
The V-shaped structure optimizes the air flow path, resulting in lower resistance when air passes through the filter (initial resistance is usually ≤180Pa), which is much lower than that of the traditional flat plate type. | Reducing the energy consumption of the air conditioning unit’s fan meets the energy-saving requirements of “green production” in new energy factories (long-term operation can save a large amount of electricity bills). |
| Compact design | Adopting “deep pleats + V-shaped arrangement”, it has a smaller volume under the same air volume and can be integrated into high-volume air handling units (AHU) or clean booths. | Save factory space (new energy factories have dense equipment and high requirements for space utilization), and be suitable for temporary clean areas such as clean booths. |
| Low leakage risk | It mostly adopts hot melt adhesive sealing or glue-free design. The frame adheres closely to the filter paper. When used in conjunction with a high-efficiency supply air outlet (FFU), the leakage rate is ≤0.1%. | Prevent unfiltered air from “short-circuiting” into the clean area to ensure stable cleanliness (especially crucial for oxygen-free clean areas such as lithium battery liquid injection). |
Iii. Specific Application Scenarios: Covering the entire process of new energy production
The application scenarios of V-shaped pleated high-efficiency filters are strongly related to the “clean demand level” of new energy production, with the core concentrated in three categories: high-clean-level process areas, terminal ventilation systems, and auxiliary clean facilities.
1. Core production process area: Directly ensures product quality
For the areas with the highest cleanliness requirements, such as Class 100 to Class 1000 (ISO 5 to 6 grades), V-type filters are usually combined with high-efficiency supply air outlets (FFUs) or laminar flow hoods to create a local Class 100 clean environment.
Lithium battery workshop
Electrode sheet stacking/winding area: A “V-shaped HEPA+FFU” combination is used to form a vertical laminar flow, preventing dust from adhering to the electrode sheet surface and causing short circuits.
Liquid injection area: “V-shaped ULPA + closed laminar flow hood” is adopted, simultaneously controlling the oxygen content (≤1%) and particles to prevent the electrolyte from reacting with impurities.
Photovoltaic workshop
Silicon wafer cleaning/coating area: V-shaped filters are integrated into the local purification system of the coating machine to prevent particle adhesion during the coating process, which may cause coating defects.
Battery cell soldering area: A horizontal laminar flow is formed through a “V-shaped HEPA + side air outlet” to prevent solder slag from contaminating the battery cell grid lines.
Hydrogen fuel cell workshop
Membrane electrode (MEA) preparation area: V-shaped ULPA filters are used to control particles smaller than 0.1μm and prevent the proton exchange membrane from being clogged by impurities.
2. Ventilation and Air Conditioning System (HVAC) : Terminal purification of air throughout the entire workshop
For large clean areas of Class 1000 to Class 10000 (ISO 6 to 7 grades) (such as lithium battery electrode coating areas and photovoltaic module assembly areas), V-type filters, as the terminal filtration link of the HVAC system, are installed at the air outlet or the end of the air duct of the air handling unit (AHU)
Working principle: Outdoor air, after going through the process of “primary filtration → medium filtration → surface cooling/heating → V-type high-efficiency filtration”, is sent to the clean workshop through air ducts and then returned to the AHU (part of the exhaust air) through the return air outlet, forming a cycle of purification.
Advantages: A single AHU can integrate multiple V-type filters (such as 6 to 12), with a total air volume reaching 10,000 to 20,000 m³/h, meeting the ventilation and cleanliness requirements of large workshops. Meanwhile, its low resistance feature reduces the load on the fan.
3. Auxiliary clean facilities: Flexibly adapt to temporary/local needs
Clean Booth (Clean Booth) : Clean booths are often used in the “temporary expansion” or “maintenance workstations” of new energy factories. Usually, 2 to 4 V-shaped HEPA filters are installed on the top, and in combination with fans, they form a local clean space (Class 100 to Class 1000), without the need to modify the factory structure.
Air shower/transfer window: Personnel and materials must pass through an air shower before entering the clean area. A small V-shaped filter is installed at the air outlet to ensure that the air for the air shower is clean. The purification unit inside the transfer window also adopts a V-shaped structure to prevent contaminants from being brought in during material transportation.
Pre-treatment of waste gas: Some waste gas from new energy production (such as the organic waste gas generated from the drying of lithium battery electrode sheets) contains tiny particles. These particles need to be filtered through V-shaped HEPA filters first before entering the activated carbon adsorption device to prevent clogging of the adsorption layer.
Iv. Key Points for Selection and Maintenance: Ensure the efficient and stable operation of the filter
When choosing and using V-shaped pleated high-efficiency filters in new energy factories, it is necessary to comprehensively consider the production process, cleanliness requirements, and system parameters to avoid “improper selection leading to substandard cleanliness” or “delayed maintenance increasing costs”.
The application scenarios of V-shaped pleated high-efficiency filters are strongly related to the “clean demand level” of new energy production, with the core concentrated in three categories: high-clean-level process areas, terminal ventilation systems, and auxiliary clean facilities.
1. Core production process area: Directly ensures product quality
For the areas with the highest cleanliness requirements, such as Class 100 to Class 1000 (ISO 5 to 6 grades), V-type filters are usually combined with high-efficiency supply air outlets (FFUs) or laminar flow hoods to create a local Class 100 clean environment.
Lithium battery workshop
Electrode sheet stacking/winding area: A “V-shaped HEPA+FFU” combination is used to form a vertical laminar flow, preventing dust from adhering to the electrode sheet surface and causing short circuits.
Liquid injection area: “V-shaped ULPA + closed laminar flow hood” is adopted, simultaneously controlling the oxygen content (≤1%) and particles to prevent the electrolyte from reacting with impurities.
Photovoltaic workshop
Silicon wafer cleaning/coating area: V-shaped filters are integrated into the local purification system of the coating machine to prevent particle adhesion during the coating process, which may cause coating defects.
Battery cell soldering area: A horizontal laminar flow is formed through a “V-shaped HEPA + side air outlet” to prevent solder slag from contaminating the battery cell grid lines.
Hydrogen fuel cell workshop
Membrane electrode (MEA) preparation area: V-shaped ULPA filters are used to control particles smaller than 0.1μm and prevent the proton exchange membrane from being clogged by impurities.
2. Ventilation and Air Conditioning System (HVAC) : Terminal purification of air throughout the entire workshop
For large clean areas of Class 1000 to Class 10000 (ISO 6 to 7 grades) (such as lithium battery electrode coating areas and photovoltaic module assembly areas), V-type filters, as the terminal filtration link of the HVAC system, are installed at the air outlet or the end of the air duct of the air handling unit (AHU)
Working principle: Outdoor air, after going through the process of “primary filtration → medium filtration → surface cooling/heating → V-type high-efficiency filtration”, is sent to the clean workshop through air ducts and then returned to the AHU (part of the exhaust air) through the return air outlet, forming a cycle of purification.
Advantages: A single AHU can integrate multiple V-type filters (such as 6 to 12), with a total air volume reaching 10,000 to 20,000 m³/h, meeting the ventilation and cleanliness requirements of large workshops. Meanwhile, its low resistance feature reduces the load on the fan.
3. Auxiliary clean facilities: Flexibly adapt to temporary/local needs
Clean Booth (Clean Booth) : Clean booths are often used in the “temporary expansion” or “maintenance workstations” of new energy factories. Usually, 2 to 4 V-shaped HEPA filters are installed on the top, and in combination with fans, they form a local clean space (Class 100 to Class 1000), without the need to modify the factory structure.
Air shower/transfer window: Personnel and materials must pass through an air shower before entering the clean area. A small V-shaped filter is installed at the air outlet to ensure that the air for the air shower is clean. The purification unit inside the transfer window also adopts a V-shaped structure to prevent contaminants from being brought in during material transportation.
Pre-treatment of waste gas: Some waste gas from new energy production (such as the organic waste gas generated from the drying of lithium battery electrode sheets) contains tiny particles. These particles need to be filtered through V-shaped HEPA filters first before entering the activated carbon adsorption device to prevent clogging of the adsorption layer.
Iv. Key Points for Selection and Maintenance: Ensure the efficient and stable operation of the filter
When choosing and using V-shaped pleated high-efficiency filters in new energy factories, it is necessary to comprehensively consider the production process, cleanliness requirements, and system parameters to avoid “improper selection leading to substandard cleanliness” or “delayed maintenance increasing costs”.
1. Core parameters for selection
| Parameter category | Selection basis | Suggestions for new energy scenarios |
| Eficacia de filtración | Select based on the cleanliness level: For Class 1000 (ISO 6 level), choose HEPA (H13/H14). For Class 100 (ISO Level 5), select ULPA (U15/U16). |
For lithium battery winding and photovoltaic coating, select U15 grade. For lithium battery coating and photovoltaic assembly, H13 grade is selected. |
| Rated air volume | The air volume of each filter should be calculated based on “clean area volume × air change rate” (for example, the air change rate for ISO grade 6 is ≥30 times /h), and the air volume of each filter should match the cross-section of the air duct. | For a 1000㎡ clean workshop (with a floor height of 3 meters), a total air volume of 90,000 m³/h is required. 90 V-type filters with a capacity of 1000 m³/h can be selected. |
| Filter paper material | Glass fiber filter paper (high efficiency, large dust holding capacity, but poor moisture resistance); Ptfe-coated filter paper (moisture-resistant, easy to clean, suitable for high-humidity environments). | For the lithium battery liquid injection area (low humidity), glass fiber is selected. Ptfe-coated film is selected for the photovoltaic cleaning area (high humidity). |
| Material del marco |
Aluminum alloy (lightweight, corrosion-resistant) Galvanized steel sheet (high strength, low cost); Stainless steel (acid and alkali resistant, suitable for corrosive environments). |
Stainless steel is selected for the hydrogen fuel cell workshop (containing acidic gases). Aluminum alloy is selected for ordinary lithium battery workshops. |
| Sealing method | Hot melt adhesive sealing (low cost, suitable for dry environments); Polyurethane foam seal (heat and moisture resistant, with better sealing effect). |
Polyurethane sealing is selected for high-temperature process areas (such as the electrode sheet drying room). For the normal temperature zone, choose hot melt adhesive for sealing. |
2. Maintain key measures
Regular inspection: The particle concentration in the clean area is detected monthly by the “particle counter”, and the filter leakage rate is detected quarterly by the “aerosol photometer” (if the leakage rate is greater than 0.1%, replacement or sealing repair is required).
Replacement as needed: When the filter resistance reaches “twice the initial resistance” (usually ≥360Pa), it should be replaced in a timely manner (new energy factories are recommended to keep 10% to 20% of the filters on standby to avoid downtime and waiting).
Replacement specification: When replacing, clean suits and gloves must be worn to avoid hand contact with the filter paper. Before installing the new filter, the frame of the supply air outlet needs to be cleaned to prevent old impurities from falling into the clean area.
Waste disposal: The waste filters from new energy factories may adsorb metal particles (such as cobalt and nickel in lithium battery production), and they need to be disposed of in accordance with the “hazardous waste” regulations to prevent environmental pollution.
V. Technological Trends: Adapting to the upgrading direction of the new energy industry
As the new energy industry upgrades towards “high capacity, high efficiency and low energy consumption”, V-shaped pleated high-efficiency filters are also evolving in the following directions:
Low resistance and energy conservation: By optimizing the fold Angle (adjusting from 45° to 60°) and using “gradient pore size filter paper” (coarse pores on the outer layer and fine pores on the inner layer), the initial resistance is further reduced (target ≤150Pa), meeting the factory’s “carbon neutrality” requirements.
Intelligent monitoring: Some manufacturers integrate “resistance sensors + wireless transmission modules” into the filters to upload resistance data to the factory MES system in real time, achieving “predictive maintenance” (no need for manual inspection).
Extreme environment resistance: Develop “high-temperature resistant (≥150℃) V-type filters” suitable for the drying room of lithium battery electrode sheets, and “acid and alkali resistant V-type filters” suitable for the electrolyte treatment area of hydrogen fuel cells.
Environmentally friendly and recyclable: Utilizing degradable filter paper and detachable frame design, it reduces the solid waste generated from discarded filters (in line with the policy requirements of “green production” in the new energy industry).
Resumen
The V-shaped pleated high-efficiency filter is the “core purification unit” of the clean space in new energy factories. Its design features perfectly match the demands of new energy production for “high cleanliness, large air volume, continuous operation, and low energy consumption”. In practical applications, only through “precise selection + standardized maintenance + technological upgrading” can its value be maximized, providing a reliable environmental guarantee for the yield improvement of products such as lithium batteries and photovoltaics.
Regular inspection: The particle concentration in the clean area is detected monthly by the “particle counter”, and the filter leakage rate is detected quarterly by the “aerosol photometer” (if the leakage rate is greater than 0.1%, replacement or sealing repair is required).
Replacement as needed: When the filter resistance reaches “twice the initial resistance” (usually ≥360Pa), it should be replaced in a timely manner (new energy factories are recommended to keep 10% to 20% of the filters on standby to avoid downtime and waiting).
Replacement specification: When replacing, clean suits and gloves must be worn to avoid hand contact with the filter paper. Before installing the new filter, the frame of the supply air outlet needs to be cleaned to prevent old impurities from falling into the clean area.
Waste disposal: The waste filters from new energy factories may adsorb metal particles (such as cobalt and nickel in lithium battery production), and they need to be disposed of in accordance with the “hazardous waste” regulations to prevent environmental pollution.
V. Technological Trends: Adapting to the upgrading direction of the new energy industry
As the new energy industry upgrades towards “high capacity, high efficiency and low energy consumption”, V-shaped pleated high-efficiency filters are also evolving in the following directions:
Low resistance and energy conservation: By optimizing the fold Angle (adjusting from 45° to 60°) and using “gradient pore size filter paper” (coarse pores on the outer layer and fine pores on the inner layer), the initial resistance is further reduced (target ≤150Pa), meeting the factory’s “carbon neutrality” requirements.
Intelligent monitoring: Some manufacturers integrate “resistance sensors + wireless transmission modules” into the filters to upload resistance data to the factory MES system in real time, achieving “predictive maintenance” (no need for manual inspection).
Extreme environment resistance: Develop “high-temperature resistant (≥150℃) V-type filters” suitable for the drying room of lithium battery electrode sheets, and “acid and alkali resistant V-type filters” suitable for the electrolyte treatment area of hydrogen fuel cells.
Environmentally friendly and recyclable: Utilizing degradable filter paper and detachable frame design, it reduces the solid waste generated from discarded filters (in line with the policy requirements of “green production” in the new energy industry).
Resumen
The V-shaped pleated high-efficiency filter is the “core purification unit” of the clean space in new energy factories. Its design features perfectly match the demands of new energy production for “high cleanliness, large air volume, continuous operation, and low energy consumption”. In practical applications, only through “precise selection + standardized maintenance + technological upgrading” can its value be maximized, providing a reliable environmental guarantee for the yield improvement of products such as lithium batteries and photovoltaics.
