Energy-Oriented Flow Analysis of Pressure Drops in H14 HEPA Minipleat Filters: A Cell-Based Geometric Model for Airflow Distribution Optimization

This study investigates the optimization of airflow distribution and pressure drops in H14 HEPA minipleat filters through the introduction of the hot-melt cell as the fundamental hydraulic unit governing local flow behavior. A coupled analytical framework integrating Falkner–Skan boundary-layer theory, Darcy–Weisbach channel friction, and Darcy porous-medium flow was developed and experimentally tested using velocity measurements obtained in a 600 m3/h test bench operating at a frontal velocity of 0.45 m/s under laminar-flow conditions. Ten primary geometric configurations and 21 hot-melt distribution scenarios (totaling 31 cases plus an optimized design case) were systematically evaluated by varying cell width (W), inlet height (Hi), and pleat length (L). Experimental and analytical results reveal significant velocity heterogeneity in the vicinity of the filter surface, which progressively decreases with distance from the filter, while localized velocity amplification is observed near the hot-melt separators. The analysis demonstrates that hydraulic diameter, pleat angle, and hot-melt spacing are the dominant parameters governing pressure drop generation and flow redistribution. Among the configurations investigated, a model-predicted optimized design (W = 46.25 mm, L = 55.00 mm, 230 pleats) yields a theoretical pressure drop reduction of up to 29.23% without significantly compromising the effective filtration area. These results provide an analytical framework for pre-prototyping optimization, although experimental verification of physical prototype validation for mechanical integrity and the preservation of initial efficiency, among other governing physical quantities, remains essential. The results demonstrate that the proposed hot-melt cell concept provides a practical engineering framework for the aerodynamic optimization of minipleat HEPA filters, enabling improved flow uniformity and reduced energy consumption in cleanroom applications.