3D Porous Separator Element for High-Compactness Fluid Filtration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional filter membranes with tubular substrates have limited compactness and flow rate due to their rectilinear channel designs, which restrict the increase in filter surface area, leading to performance limitations in separation processes.
Innovation Solution
The development of novel separator elements with a porous, rigid single-piece substrate featuring interconnected three-dimensional structures that create multiple flow circuits, increasing the filter surface area and compactness by up to 2000 m2/m3, achieved through additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional tubular substrates with rectilinear channels are used, then the substrate structure is simple and easy to manufacture, but the filter surface area is limited and compactness is low
Solution Approach 1:
The patent transitions from conventional two-dimensional rectilinear channels to three-dimensional interconnected channels. The substrate includes a three-dimensional network of channels extending in multiple directions (x, y, z axes) rather than simple linear paths, enabling significantly increased filter surface area within the same volume while maintaining structural integrity through the interconnected nature of the channels.
Solution Approach 2:
The patent implements nested channel structures where smaller diameter channels are positioned within or alongside larger diameter channels. This nesting arrangement allows multiple flow paths to occupy the same spatial envelope, effectively multiplying the filter surface area without proportionally increasing the overall substrate volume, thereby improving compactness.
2Productivity
If the number of channels is increased to increase filter surface area, then the separation performance improves, but the substrate becomes more fragile and mechanical strength decreases
Solution Approach 1:
The patent varies the wall thickness and channel dimensions locally throughout the substrate structure. Thicker walls are positioned in regions requiring higher mechanical support, while thinner walls are used where structural demands are lower but filter surface area is prioritized. This local optimization allows increased channel density without uniformly compromising mechanical strength.
Solution Approach 2:
The substrate is formed as a composite structure combining multiple materials with different properties. The base substrate material provides mechanical strength and structural integrity, while separate filter coating layers applied to the channel surfaces provide the separation function. This composite approach allows independent optimization of mechanical properties and separation performance.
3Area of stationary object
If conventional extrusion and sintering methods are used, then the manufacturing process is established and reliable, but the filter surface area cannot be increased beyond a ceiling
Solution Approach 1:
The patent fundamentally changes the manufacturing approach from conventional extrusion and sintering to additive manufacturing (3D printing). This parameter change in the fabrication process enables the creation of complex three-dimensional channel networks that would be impossible to produce with traditional methods, allowing filter surface area to exceed previous ceilings while maintaining manufacturing reliability through digital process control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the compactness and flow rate of filter membranes, allowing for more efficient separation processes by increasing the filter surface area without compromising mechanical strength, thereby improving the effectiveness of fluid treatment in various industrial applications.
Implementation Method 1
a porous rigid single-piece substrate made out of a single material and presenting firstly, at its periphery, a perimeter wall that is continuous between an inlet for the fluid medium for treatment at one end of the porous substrate and an outlet for the retentate at the other end of the porous substrate
Implementation Method 2
Depending on the size of the pores, these techniques are referred to as microfiltration, ultrafiltration, or nanofiltration
Implementation Method 3
Depending on the size of the pores, these techniques are referred to as microfiltration, ultrafiltration, or nanofiltration
Implementation Method 4
Depending on the size of the pores, these techniques are referred to as microfiltration, ultrafiltration, or nanofiltration
Data Source
AI summary
A separator element comprising a porous rigid single-piece substrate (2) presenting firstly, at its periphery, a perimeter wall (21) that is continuous between an inlet (4) for the fluid medium for treatment at one end of the porous substrate and an outlet (5) for the retentate at the other end of the porous substrate, and secondly, internally, a surface covered by a separator layer (6) and defining an open structure made up of empty spaces (3) for passing a flow of the fluid medium for treatment. The empty spaces (3) are arranged in the porous substrate so as to create within the porous substrate a first flow network (R1) for the fluid medium for treatment, having at least two interconnected flow circuits (R11, R12) for the fluid medium between the inlet (4) and the outlet (5) of the porous substrate.