Carbon Fiber Nonwoven Composition for Solvent Adsorption Durability
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Solution Overview
Problem
Nonwoven fabrics for odor gas adsorption face challenges in achieving balanced performance in terms of adsorption, durability, and thermal resistance due to the blending ratios of hot-melt fibers with activated carbon fibers, leading to insufficient adsorption or reduced durability and thermal resistance.
Innovation Solution
A nonwoven fabric composed of specific carbon fibers or carbon fiber precursors and other fibers, blended at a specific ratio, providing superior adsorption performance, durability, and thermal resistance, with a blend ratio of 50:50 to 99:1 by mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crossflow ultrafiltration membrane module is used for organic solvent recovery, then the membrane life is extended and concentration polarization is reduced, but the device complexity increases due to additional modules required
Solution Approach 1:
The ultrafiltration system is divided into multiple modules arranged in series, where each module processes a portion of the feed solution. This segmentation allows the system to handle larger volumes while maintaining low crossflow velocities that extend membrane life and reduce concentration polarization, without requiring excessively high flow rates in a single complex module.
Solution Approach 2:
A multi-module configuration acts as an intermediary approach between single-module systems and complex continuous systems. The series arrangement of multiple simpler modules achieves the performance benefits of extended membrane life and reduced concentration polarization while maintaining manageable device complexity through modular design.
2Productivity
If membrane modules are arranged in parallel to increase productivity, then the processing capacity increases, but concentration polarization increases and membrane life decreases
Solution Approach 1:
Instead of using fewer parallel modules with high flow rates, the system uses multiple modules arranged in series to achieve the required productivity. This segmentation allows each module to operate at lower, more gentle flow rates that extend membrane life while collectively processing the required volume of feed solution.
Solution Approach 2:
The system transitions from a parallel arrangement (two-dimensional scaling) to a series arrangement (one-dimensional scaling along the flow path). This dimensional change in module configuration allows productivity to increase through extended processing time rather than increased flow rate, thereby protecting membrane life.
3Reliability
If membrane modules are arranged in series to extend membrane life, then the membrane life is extended, but the required membrane area increases
Solution Approach 1:
The system changes the operating parameters of each module in the series arrangement, specifically maintaining low crossflow velocities and appropriate residence times. This parameter optimization allows each unit membrane area to be used more efficiently, reducing the total membrane area required compared to high-velocity single-pass systems.
Solution Approach 2:
The series arrangement enables continuous processing where the feed solution passes through multiple modules sequentially, allowing complete utilization of the membrane surface area across all modules. This continuous action at optimized flow rates maximizes the effective use of total membrane area while extending membrane life through gentle operating conditions.
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
The nonwoven fabric achieves high adsorption performance for odor gases, enhanced durability, and improved thermal resistance, effectively adsorbing and desorbing organic solvents, suitable for organic solvent recovery applications.
Implementation Method 1
a porous substrate, and a fibrous layer having a porous structure in which at least a part of pores is filled with a resin granule
Implementation Method 2
the fibrous layer having a porous structure in which at least a part of pores is filled with a resin granule
Data Source
AI summary
The nonwoven fabric of the present invention is a nonwoven fabric containing: a carbon fiber or carbon fiber precursor (A) each having an average fiber diameter of 10 µm or more and 30 µm or less, a tensile strength (1) of 40 N/mm2 or more and 300 N/mm2 or less, and an elongation percentage of 0% or more and 10% or less; and a fiber (B) having an average fiber diameter of 5 µm or more and 30 µm or less and a tensile strength (2) of 200 N/mm2 or more and 600 N/mm2 or less, provided that the tensile strength (2) is higher than the tensile strength (1), wherein the blend ratio between the carbon fiber or carbon fiber precursor (A) and the fiber (B) ((A):(B)) is 50:50 to 99:1 on mass basis, the carbon fiber or carbon fiber precursor (A) is an activated carbon fiber or an infusibilized fiber, and the fiber (B) is a carbon fiber or a carbon fiber precursor.