Composite Filter Media With Coarse Interlayer
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Solution Overview
Problem
Fluid filtration devices are prone to clogging due to trapped particles and contaminants, leading to reduced service life and increased manufacturing costs, with the addition of a prefilter increasing size and complexity.
Innovation Solution
A composite filter media with a coarse porous interlayer between fiber-containing filter layers, where the interlayer has a pore size 2 to 100 times larger than the adjacent layers, enhancing dirt-holding capacity and service life while reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a prefilter with coarser structure is added to protect the final filter, then the service life of the final filter is increased, but the total space occupied by the filtration system increases
Solution Approach 1:
The patent combines the prefilter and final filter into a single composite filter cartridge, integrating multiple filtration functions (coarse prefiltration and fine final filtration) into one unified structure. This merging eliminates the need for separate prefilter housings and supports, thereby increasing service life while minimizing the total space occupied by the filtration system.
Solution Approach 2:
The patent uses composite filter media consisting of different porous layers with varying pore sizes bonded together. The composite structure includes a coarse prefilter layer and a finer final filter layer, creating a multi-functional filtration system that provides both prefiltration and final filtration capabilities within a single compact cartridge.
2Duration of action of stationary object
If a prefilter with coarser structure is added to remove large particles, then the service life of the final filter is increased, but the manufacturing cost increases
Solution Approach 1:
The patent combines the prefilter and final filter into a single composite filter cartridge, integrating multiple filtration functions (coarse prefiltration and fine final filtration) into one unified structure. This merging eliminates the need for separate prefilter housings and supports, thereby increasing service life while minimizing the total space occupied by the filtration system.
Solution Approach 2:
The patent uses composite filter media consisting of different porous layers with varying pore sizes bonded together. The composite structure includes a coarse prefilter layer and a finer final filter layer, creating a multi-functional filtration system that provides both prefiltration and final filtration capabilities within a single compact cartridge.
3Volume of stationary object
If filter layers are layered directly over each other without interlayer, then the filter structure is compact, but the dirt holding capacity is reduced due to clogging
Solution Approach 1:
The patent introduces a porous interlayer with intermediate pore size between the coarse prefilter layer and the fine final filter layer. This interlayer acts as a mediator that facilitates smooth fluid flow and particle transition, preventing direct contact between the fine filter media and large particles, thereby reducing clogging and enhancing dirt-holding capacity while maintaining a compact filter structure.
Solution Approach 2:
The patent employs porous interlayers with controlled pore sizes between the filter layers. These porous materials allow fluid to pass through while trapping particles of appropriate sizes, creating a graded filtration structure that maintains compactness while significantly improving dirt-holding capacity by preventing clogging of the fine filter layer.
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 composite filter media significantly increases throughput capacity and service life by trapping particles effectively, reducing clogging and maintaining fluid flow, while minimizing size and manufacturing costs.
Implementation Method 1
Fluid filters designed for removal of unwanted particulates and contaminants are susceptible to clogging due to the fact that as particles and contaminants become trapped in the filter medium, fluid pathways become closed or restricted.
Implementation Method 2
a coarse porous interlayer located between at least two fiber containing porous filter layers
Implementation Method 3
the interlayer has a pore size 2 to 100 times larger than the adjacent layers, enhancing dirt-holding capacity and service life while reducing size and cost
Data Source
AI summary
A fluid filtration device containing a composite filter media having a coarse porous polymeric nonwoven interlayer located between first and second polymeric fiber containing filter mats. The fiber diameters of the fibers in the first and second filter mats are different from each other, and each filter mat has a different pore size rating. The first and second polymeric fibers in the filter mats can be electrospun nanofibers. The interlayer has a coarser pore size when compared to the either the first or second filter mats, such that the resulting composite media has an increased dirt holding capacity compared to filter layers that are layered directly over each other without the presence of a coarse interlayer therebetween.