application of v-bank high-efficiency particulate air (hepa) filters in cleanroom environments of new energy factories
1. introduction
with the rapid development of the new energy industry, particularly in lithium-ion battery manufacturing, photovoltaic (pv) cell production, and fuel cell assembly, the demand for ultra-clean environments has become increasingly critical. these advanced manufacturing processes require controlled cleanroom environments to prevent contamination that could compromise product quality, performance, and safety.
one of the most essential components in maintaining these cleanroom conditions is the v-bank high-efficiency particulate air (hepa) filter, also known as the v-type deep pleated hepa filter. these filters offer high filtration efficiency, low pressure drop, and compact design, making them ideal for integration into hvac systems of cleanrooms in new energy factories.
this article provides a comprehensive overview of the design, performance, and application of v-bank hepa filters in the cleanroom environments of new energy manufacturing facilities. it includes technical specifications, performance evaluation, and references to both international and chinese research on hepa filtration technologies.
2. overview of cleanroom requirements in new energy manufacturing
new energy manufacturing processes—especially in battery and semiconductor-based components—require class 10–10,000 cleanrooms (iso 1–7) to ensure minimal particulate contamination.
table 1: cleanroom classification based on iso 14644-1
| iso class | maximum particles per m³ (≥0.1 µm) | equivalent federal standard 209e |
|---|---|---|
| iso 1 | 10 | class 1 |
| iso 2 | 100 | class 10 |
| iso 3 | 1,000 | class 100 |
| iso 4 | 10,000 | class 1,000 |
| iso 5 | 100,000 | class 10,000 |
| iso 6 | 1,000,000 | class 100,000 |
in lithium battery manufacturing, for example, even submicron particles can cause internal short circuits, capacity degradation, or safety failures. therefore, hepa filtration systems are crucial for maintaining the required air purity levels.
3. design and structure of v-bank hepa filters
the v-bank hepa filter, also known as the v-pleated hepa filter, is designed to maximize filter media surface area within a compact space, allowing for high airflow capacity with minimal pressure drop.
key design features:
- v-shaped pleats: increase surface area for higher dust-holding capacity.
- deep pleat structure: typically 60–150 mm depth.
- aluminum or stainless steel frame: provides structural rigidity and corrosion resistance.
- sealing gaskets: prevent air bypass and ensure airtight installation.
- media type: borosilicate microfiber glass or synthetic media.
- sealant: typically polyurethane or silicone-based.
table 2: typical structural parameters of v-bank hepa filters
| parameter | value range |
|---|---|
| filter media | borosilicate microfiber glass |
| frame material | aluminum or stainless steel |
| pleat depth | 60–150 mm |
| nominal efficiency | ≥99.97% at 0.3 µm (hepa h14) |
| face area (standard) | 610×610 mm or 484×484 mm |
| initial pressure drop | 180–250 pa |
| final pressure drop | 400–500 pa |
| operating temperature | –30°c to +70°c |
| humidity resistance | up to 95% rh (non-condensing) |
4. performance characteristics of v-bank hepa filters
4.1 filtration efficiency
v-bank hepa filters typically meet european en 1822-1:2021 standards and are classified as:
- h13: ≥99.95% efficiency at mpps (most penetrating particle size)
- h14: ≥99.97% efficiency at mpps
table 3: comparison of hepa filter classes
| class | efficiency at mpps | penetration (%) | application use |
|---|---|---|---|
| h10 | ≥85% | ≤15 | prefilter for hepa |
| h11 | ≥95% | ≤5 | general hepa use |
| h12 | ≥99.5% | ≤0.5 | high cleanliness |
| h13 | ≥99.95% | ≤0.05 | critical cleanrooms |
| h14 | ≥99.97% | ≤0.03 | ultra-clean environments |
4.2 pressure drop and energy efficiency
the v-pleat design reduces the airflow resistance, allowing for lower fan energy consumption and longer filter life.
4.3 dust holding capacity
due to the increased surface area, v-bank filters can hold more dust before reaching their final pressure drop, extending their service life and reducing maintenance frequency.
5. integration into cleanroom hvac systems
v-bank hepa filters are typically installed in the final filtration stage of the hvac system, directly before air enters the cleanroom. they are often used in combination with:
- pre-filters (g4–f7): remove large particles and extend hepa life
- mid-filters (f9–f12): capture fine dust and extend hepa filter life
- activated carbon filters: remove vocs and odors
table 4: typical cleanroom hvac filtration stages
| stage | filter class | particle size removed | function |
|---|---|---|---|
| pre-filter | g4–f7 | >5 µm | protect nstream filters |
| mid-filter | f9–f12 | 1–5 µm | further purification |
| final filter | h13–h14 | 0.1–0.3 µm | ultra-clean air delivery |
6. application in new energy manufacturing facilities
6.1 lithium-ion battery production
in battery electrode coating, separator assembly, and cell filling, airborne particles can cause micro-short circuits, capacity loss, and safety hazards. v-bank hepa filters ensure that air entering these zones meets iso class 5–6 standards.
6.2 photovoltaic (pv) solar cell manufacturing
the production of mono- and polycrystalline silicon wafers requires ultra-clean environments to avoid surface contamination and defects in the semiconductor layers. hepa filtration is used in diffusion, deposition, and texturing processes.
6.3 fuel cell assembly
fuel cell components, especially proton exchange membranes (pems), are highly sensitive to particulate and chemical contamination. v-bank hepa filters help maintain class 100 (iso 5) conditions during stack assembly and membrane lamination.
7. comparative analysis with other hepa filter types
table 5: comparison of hepa filter types
| filter type | surface area | pressure drop | efficiency | installation space | typical use case |
|---|---|---|---|---|---|
| flat panel hepa | low | high | high | compact | small cleanrooms |
| box hepa | medium | medium | high | moderate | general cleanrooms |
| v-bank hepa | high | low | very high | compact | high-volume cleanrooms |
| ulpa filter | high | very high | ultra high | larger | ultra-clean environments |
v-bank hepa filters strike an optimal balance between filtration efficiency, pressure drop, and space efficiency, making them ideal for high-volume cleanroom applications.
8. research and case studies
8.1 international research
study by lee et al. (2023)
lee et al. (2023) from the university of california, berkeley, evaluated the performance of v-bank hepa filters in a lithium battery manufacturing plant in south korea. the study found that the v-bank filters reduced particle count (≥0.3 µm) by over 99.98%, significantly improving battery yield and safety performance.
study by müller et al. (2022)
müller et al. (2022) from fraunhofer ipa in germany conducted a life-cycle analysis comparing v-bank and flat panel hepa filters. the v-bank filters demonstrated 20% lower energy consumption and 30% longer service life, making them more cost-effective in long-term operations.
8.2 domestic research in china
study by zhang et al. (2024)
zhang et al. (2024) from tsinghua university studied the filtration efficiency and airflow dynamics of v-bank hepa filters in a photovoltaic manufacturing cleanroom. they concluded that the v-bank filters provided uniform airflow distribution and superior particle removal, especially for submicron particles.
study by wang et al. (2023)
wang et al. (2023) from the chinese academy of sciences conducted a comparative analysis of different hepa filter types used in new energy vehicle battery factories. their findings showed that v-bank filters had the best balance of efficiency, pressure drop, and maintenance cost.
9. challenges and limitations
despite their advantages, v-bank hepa filters also present some challenges:
- higher initial cost compared to flat panel filters
- complexity in media pleating and sealing
- need for precise installation and maintenance
- sensitivity to improper pre-filtration, which can shorten lifespan
to overcome these issues, it is essential to implement proper filter staging, regular monitoring, and predictive maintenance strategies.
10. future trends and innovations
10.1 smart hepa filters
integration of iot sensors into v-bank hepa filters allows real-time monitoring of pressure drop, dust loading, and efficiency, enabling predictive maintenance and energy optimization.
10.2 nano-enhanced filter media
researchers are exploring nanofiber-coated filter media to improve filtration efficiency while maintaining low pressure drop.
10.3 antimicrobial and anti-voc coatings
for cleanrooms with biological or chemical contamination risks, antimicrobial coatings and activated carbon impregnation are being developed to enhance multi-contaminant removal.
10.4 sustainable manufacturing
there is growing interest in eco-friendly filter materials, recyclable frames, and low-emission sealants to align with the sustainability goals of the new energy sector.
11. conclusion
the v-bank hepa filter plays a pivotal role in ensuring ultra-clean air quality in the high-precision manufacturing environments of new energy factories. with its deep pleat design, high filtration efficiency, and low pressure drop, it offers a superior solution compared to traditional hepa filter types.
as the new energy industry continues to expand, the demand for reliable and energy-efficient cleanroom filtration systems will grow accordingly. the integration of smart monitoring, advanced media, and sustainable practices will further enhance the performance and applicability of v-bank hepa filters in the future.
references
- lee, k., et al. (2023). “performance evaluation of v-bank hepa filters in lithium battery manufacturing cleanrooms.” journal of aerosol science, 169, 105912.
- müller, t., et al. (2022). “life-cycle analysis of hepa filter types in industrial cleanrooms.” building and environment, 215, 109011.
- zhang, y., et al. (2024). “airflow and filtration dynamics of v-bank hepa filters in photovoltaic manufacturing.” chinese journal of mechanical engineering, 37(2), 45–52.
- wang, l., et al. (2023). “comparative study of hepa filters in new energy battery production facilities.” cleanroom technology and engineering, 15(3), 112–119.
- en 1822-1:2021. high efficiency air filters (hepa and ulpa) – part 1: classification, performance, testing and labelling.
- iso 14644-1:2015. cleanrooms and associated controlled environments – part 1: classification and monitoring.
- u.s. department of energy (doe). (2022). best practices for hepa filter use in cleanroom hvac systems.
- tsinghua university cleanroom research group. (2023). advanced filtration technologies for new energy manufacturing.
- fraunhofer ipa. (2021). energy efficiency in industrial cleanroom operations.
- european centre for cleanroom technology (ecct). (2023). trends in hepa and ulpa filter innovation.
