Composite Microporous Filter Material Using Polysulfoneamide and P84 Fibers
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Solution Overview
Problem
The heavy chemical industry faces environmental pollution due to high emission densities of heat gas and respirable particulates, requiring a filter material that is both temperature-resistant and corrosion-resistant while maintaining high filter precision at a lower manufacturing cost, as using solely P84 fiber is expensive and increases costs.
Innovation Solution
A composite microporous filter material is developed, comprising a base-cloth layer and adhesion layers made of polysulfoneamide and P84 fibers, with a specific density and fiber proportion, using needle punching and spunlacing techniques to enhance filter efficiency and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the filter material is made of only P84 fiber to achieve high temperature resistance and filter precision, then the filter performance is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies composite materials by combining P84 fibers with polysulfoneamide fibers in a blended structure. The P84 fibers provide high-temperature resistance and filtration precision, while the polysulfoneamide fibers reduce manufacturing cost. This composite approach allows the filter material to maintain required performance while lowering overall material cost compared to using 100% P84 fiber.
Solution Approach 2:
The patent implements local quality by creating a blended fiber structure where P84 fibers are distributed within a polysulfoneamide matrix. Rather than uniformly using expensive P84 throughout, the P84 fibers are strategically positioned to provide filtration precision where needed, while polysulfoneamide fills other regions to reduce cost. This localized application optimizes the balance between performance and cost.
2Reliability
If P84 fiber is used to achieve temperature resistance and corrosion resistance, then the filter durability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent uses composite materials combining P84 fibers with polysulfoneamide fibers. The P84 component provides the required temperature resistance and corrosion resistance for reliability, while the polysulfoneamide component reduces manufacturing cost. This composite structure maintains the durability requirements without the prohibitive cost of 100% P84 construction.
3Manufacturing precision
If the fiber density is increased to improve filter precision for PM2.5 particles, then the filtration efficiency is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies composite materials with a blended structure of P84 and polysulfoneamide fibers to achieve the required fiber density for PM2.5 filtration. The P84 fibers contribute to the dense structure needed for high precision, while the polysulfoneamide fibers provide cost-effective volume, enabling the achievement of high fiber density without the prohibitive cost of 100% P84 construction.
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 material effectively filters respirable particulates like PM10, PM5, and PM2.5, achieving high filter precision and efficiency while reducing manufacturing costs by utilizing polysulfoneamide fibers to enhance temperature and corrosion resistance.
Implementation Method 1
The upper adhesion layer and the lower adhesion layer are attached to two sides of the base-cloth layer by entangling which is adopted by needle punching, spunlacing, or a combination thereof
Data Source
AI summary
The composite microporour filter material comprises a base-cloth layer, an upper adhesion layer attached to a top side of the base-cloth layer, and a lower adhesion layer attached to a bottom side of the base-cloth layer. The base-cloth layer is made of either polymide yarn base-cloth, polysulfoneamide yarn base-cloth, or polytetrafluoroethylene filament base-cloth. The upper adhesion layer is made of a mixture of polysulfoneamide short-staple and polymide short-staple; the lower adhesion layer is made of a pure polysulfoneamide short-staple. The upper adhesion layer and the lower adhesion layer are attached to two sides of the base-cloth layer by entangling which is adopted by needle punching, spunlacing or a combination thereof. The present filter material is temperature-resistant and corrosion-resistant and has features of a low manufacturing cost and the high filter precision.