The modular high-efficiency filter (also known as “modular high-efficiency filter”) is a filtration device designed for large supply air ceilings and high-volume cleanroom scenarios. By integrating multiple independent HEPA/ULPA filter units (filter elements) within a unified framework, it ADAPTS to different size and air volume requirements. Based on the actual operation and maintenance scenarios of cleanrooms, its advantages and disadvantages are as follows, taking into account both technical features and practical feasibility:
I. Core Advantages (Key Characteristics for Adapting to High-Demand Clean Environments)
1. Strong air volume adaptability, meeting the demands of large-scale scenarios
The air volume of a single filter unit is typically 500-2000m³/h. By increasing or decreasing the number of units or customizing the frame size, the air volume can be flexibly configured from 1000-10000m³/h or more, perfectly matching large operating rooms, pharmaceutical filling workshops, semiconductor clean workshops and other supply air ceilings that require high air supply volume.
Compared with a single large high-efficiency filter, the modular design can avoid the problem of uneven airflow caused by insufficient air volume of a single device, and is especially suitable for large-area supply air ceilings (such as laminar flow areas of ≥10 square meters).
2. The filtration efficiency is stable and the sealing performance is more reliable
Each filter unit is independently encapsulated and sealed with silicone or polyurethane integral foaming, closely adhering to the frame. The air leakage rate can be controlled at ≤0.01% (HEPA level), which is far superior to the sealing effect of traditional spliced filters and effectively avoids secondary pollution in the clean area.
Supports HEPA (H13-H14 grade) or ULPA (U15-U17 grade) filter material combinations, and can be flexibly matched according to the cleanliness grade requirements (such as ULPA units for semiconductor workshops and HEPA units for pharmaceutical B-grade areas), with strong consistency in filtration efficiency.
3. Low maintenance cost and convenient and efficient replacement
Adopt the “modular replacement” mode: when the pressure difference of a certain unit exceeds the standard or it is damaged, that unit can be replaced separately without the need to disassemble the entire filter frame, reducing downtime (for example, for a 10-unit combined filter, replacing a single unit only takes 30 minutes, while replacing the entire unit takes 2-3 hours).
Reduce spare parts costs: There is no need to stockpile entire large filters; only individual filter units need to be kept as backups. The inventory pressure is small, making it particularly suitable for long-term operation and maintenance scenarios.
4. Compact structure, suitable for complex installation Spaces
The frame is made of aluminum alloy or stainless steel, with a compact design. It can be customized according to the size and shape of the supply air ceiling (such as square or irregular), without occupying too much additional ceiling space. It is suitable for the installation environment with dense pipelines in the clean room ceiling.
Some products support “superimposed installation”, which can increase the filtration area in a limited space, reduce air flow resistance (under the same air volume, the resistance of the combined filter is 10%-20% lower than that of a single large filter), and reduce the energy consumption of the fan.
5. High operational stability and dispersed fault risks
The multi-unit parallel design ensures that even if a single unit malfunctions (such as filter material damage or blockage), the rest of the units can still operate normally, preventing the entire clean area from being paralyzed due to the failure of a single filter (especially in critical production scenarios, such as vaccine filling workshops).
The overall strength of the frame is high, with strong anti-deformation ability. It can withstand wind pressure changes and slight vibrations inside the ceiling and is suitable for long-term continuous operation scenarios (such as 24-hour non-stop production in semiconductor workshops).
Ii. Main Disadvantages (Key Usage Restrictions to Focus on
1. The initial investment cost is relatively high
The frame design, modular sealing process and manufacturing cost of independent filter units of the combined filter are higher than those of a single large high-efficiency filter with the same air volume. The initial procurement cost is about 20% to 40% higher. It is suitable for scenarios with high requirements for operational stability and maintenance efficiency (such as operating rooms and high-output electronic workshops), but its cost performance is not advantageous in small clean rooms.
2. The installation accuracy requirements are strict
The installation surface of the frame and the supply air ceiling should be kept flat. If the installation deviation exceeds ±2mm, it may cause the seal between the unit and the frame to fail. Meanwhile, the installation positions of each unit need to be aligned to prevent air flow short circuits, which requires a relatively high level of technical skills from the installers (professional teams are needed to operate).
3. Airflow uniformity depends on design optimization
If the unit layout is unreasonable (such as the distance between edge units being too large), it may lead to uneven air supply from the air supply panel. The arrangement of the units (such as uniform distribution + edge denser) needs to be optimized through fluid simulation during the design stage; otherwise, it may affect the stability of the airflow in the clean area (for example, if the laminar wind speed deviation in the operating room exceeds ±10%).
4. It is not suitable for scenarios with low air volume
For small supply air ceilings (such as ≤3 square meters, air volume ≤1000m³/h), the modular advantage of the combined filter cannot be reflected. Instead, due to the complex frame structure, the installation is cumbersome and it is not as simple and practical as a single small high-efficiency filter.
5. Long-term operation requires attention to the aging of the frame seal
The sealing strips between the frame and the ceiling, as well as between the units and the frame, may age and crack when exposed to a clean room temperature and humidity environment for a long time (especially in high-humidity scenarios such as biological laboratories). Regular inspections are required (it is recommended to do so once every quarter), otherwise it may lead to air leakage and affect the cleanliness.
Iii. Applicable Scenarios and Selection Suggestions
1. Scenarios where combined high-efficiency filters are preferred
Large-scale clean rooms (supply air ceiling area ≥5 square meters, air volume ≥3000m³/h) : such as operating rooms, pharmaceutical filling workshops, semiconductor wafer factories;
Key production/experimental scenarios (prolonged downtime is not allowed) : such as vaccine production, gene sequencing laboratories, electronic chip manufacturing;
For scenarios with high maintenance efficiency requirements, such as factories with centralized operation and maintenance of multiple clean areas, it is necessary to reduce the replacement time and labor intensity.
2. Scenarios not recommended for selection
Small clean rooms (supply air ceiling area ≤3 square meters, air volume ≤1000m³/h) : such as small super-clean workbenches in laboratories, local clean areas;
Scenarios with limited budgets and low requirements for maintenance efficiency: such as ordinary food processing workshops and clean warehouses.
Summary
The core advantages of the combined high-efficiency filter lie in “modular maintenance, high stability and strong adaptability”, making it suitable for use in the supply air ceilings of large and critical clean rooms. It can effectively reduce long-term operation and maintenance costs and failure risks. Its drawbacks mainly lie in the initial investment and installation requirements, which need to be comprehensively selected based on the scale of the cleanroom, the usage scenarios and the budget. In practical applications, it is recommended to give priority to choosing original factory-customized products (to ensure compatibility between the unit and the frame), and have a professional team handle installation and commissioning to maximize their technical advantages.
