Additive Manufacturing Filtration Media with Undulating Segmented Layers
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Solution Overview
Problem
Current additive manufacturing technologies are limited in creating filtration media with complex geometries and small pore sizes suitable for removing contaminants from fluids used in earthmoving, construction, and mining equipment, leading to inadequate filtration efficiency and throughput.
Innovation Solution
The use of 3D printing technology to create filters with undulating layers and segmented structures, allowing for precise control of pore size and geometry, and varying print settings such as infill angle and layer height to achieve finer porosity and increased debris holding capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional additive manufacturing is used to create filter media, then solid structures are produced, but porous filtration media with small pore sizes cannot be achieved
Solution Approach 1:
The patent applies porous materials by designing the filter media itself as a porous structure created through additive manufacturing. The undulating layers with controlled infill patterns create inherent porosity with specific pore sizes (e.g., 0.003 to 0.025 inches) that enable effective filtration while maintaining structural integrity. This resolves the contradiction by making the manufactured material itself porous rather than attempting to create pores in solid material.
Solution Approach 2:
The patent employs parameter changes by systematically varying additive manufacturing parameters including infill density, infill angle, layer height, and support structure configuration to achieve desired pore size distributions. By adjusting these parameters, the process can produce different pore sizes (from 0.003 to 0.025 inches) and porosity levels, enabling precise control over filtration characteristics while maintaining manufacturability.
2Reliability
If complex geometries are used in filter media, then filtration efficiency improves, but manufacturing capability is exceeded
Solution Approach 1:
The patent applies segmentation by dividing the filter media into multiple undulating layers, each with potentially different infill patterns, angles, and porosity characteristics. This allows complex overall geometry to be built from simpler repeating units that are within manufacturing capabilities. Each layer can be independently optimized for specific filtration functions while maintaining manufacturability through standardized layer construction.
Solution Approach 2:
The patent employs another dimension by creating undulating three-dimensional layers with varying heights, angles, and curvatures instead of flat two-dimensional filters. This adds vertical complexity and flow path complexity that enhances filtration efficiency through increased surface area and tortuous flow paths, while the layer-by-layer additive manufacturing process makes this complex geometry manufacturable.
3Reliability
If smaller pore sizes are achieved, then contaminant removal improves, but fluid throughput decreases
Solution Approach 1:
The patent applies local quality by creating different pore sizes and infill densities in different regions or layers of the filter media. Some layers can have smaller pores for fine particle removal while other layers have larger pores for higher throughput. This spatial variation in local properties allows the filter to simultaneously achieve high contaminant removal efficiency and maintain adequate fluid throughput by optimizing different zones for different functions.
Solution Approach 2:
The patent employs composite materials by combining multiple materials with different properties in the filter media construction. Different polymers, fillers, or material compositions can be used in different layers to achieve varying pore sizes, mechanical strengths, and flow characteristics. This material composition variation enables the filter to balance fine filtration with high throughput by using material properties rather than just geometric constraints.
4Quantity of substance
If undulating layers with varying infill patterns are used, then debris holding capacity increases, but manufacturing time increases
Solution Approach 1:
The patent applies periodic action by using repeating patterns of undulating layers with alternating or systematic infill configurations. Rather than creating entirely unique complex geometries, the design uses periodic repetition of optimized layer patterns that capture debris effectively. This periodic structure increases debris holding capacity through multiple capture zones while reducing manufacturing time by repeating proven patterns rather than creating novel geometries throughout.
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 approach enables the production of filtration media with improved pore sizes and efficiency, enhancing the ability to remove contaminants and extend the lifespan of equipment by increasing the debris holding capacity and fluid throughput.
Implementation Method 1
A filter medium is produced using an additive manufacturing process. The additive manufacturing process may include depositing material in a layer by layer fashion
Implementation Method 2
The filter medium may be used to remove contaminants from a fluid
Data Source
AI summary
A method for manufacturing a filter medium includes providing a computer-readable three-dimensional model of the filter medium including a plurality of segments, each segment of the three-dimensional model being configured to be converted into a plurality of slices that each define a cross-sectional layer of the filter medium, each segment including an undulating layer extending along a predetermined direction that is different than the predetermined direction of the undulating layer of the other segment; and successively forming each layer of the filter medium by additive manufacturing.