Depth Filter for Metal Ion Removal
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Solution Overview
Problem
Conventional methods are inefficient in reducing metal ion content in solutions used for electronic component manufacturing to extremely low levels, such as below the ppb level, and often require multiple work processes, making them inefficient.
Innovation Solution
A depth filter made from a porous molded article composed of dried gel powder containing an ion exchange resin with a sulfonic acid group and a nitrogen-containing chelating resin, which efficiently removes metal ions from treatment liquids, is used in conjunction with a second filter to achieve low metal ion content solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to reduce metal ion content, then some metal ions are removed, but the metal ion content cannot be reduced to extremely low levels (below ppb level)
Solution Approach 1:
The patent uses a composite filter medium comprising both ion exchange resin and chelating resin components. The ion exchange resin removes metal ions through ion exchange mechanisms, while the chelating resin provides additional metal ion binding through chelation. This composite approach enables the filter to achieve extremely low metal ion content (below ppb level) that cannot be achieved by conventional single-method approaches, directly resolving the contradiction between manufacturing precision and removal efficiency.
2Manufacturing precision
If multiple work processes are used to remove metal ions, then metal ion content is reduced, but the process becomes inefficient and complex
Solution Approach 1:
The patent merges multiple metal ion removal mechanisms (ion exchange and chelation) into a single integrated filter unit. The filter medium contains both ion exchange resin and chelating resin components that work simultaneously or sequentially within one filter element, eliminating the need for multiple separate treatment processes. This consolidation achieves extremely low metal ion content while simplifying the overall process, directly addressing the contradiction between manufacturing precision and device complexity.
3Manufacturing precision
If ion exchange resin is used to remove metal ions, then metal ions are removed, but the resin may shed and become an impurity
Solution Approach 1:
The patent employs a composite filter medium where ion exchange resin is combined with chelating resin and likely a supporting matrix material. This composite structure provides mechanical stability that prevents resin shedding while maintaining the metal ion removal capability. The chelating resin component also contributes to metal ion binding, providing redundancy that ensures low metal ion content even if some resin particles shed, thus resolving the contradiction between manufacturing precision and harmful factors.
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 filter effectively reduces metal ion content to extremely low levels, improving the stability of electronic component manufacturing solutions by minimizing ion exchange resin shedding and maintaining strength during dimensional changes.
Implementation Method 1
The dried gel powder contains an ion exchange resin including a sulfonic acid group
Implementation Method 2
The dried gel powder contains a nitrogen-containing chelating resin
Data Source
AI summary
To provide a filter capable of efficiently removing metal ions in a treatment liquid, and capable of easily obtaining a solution having an extremely low metal ion content. A depth filter includes a porous molded article. The porous molded article is a sintered material of mixed powder or a swollen material of the sintered material. The mixed powder contains dried gel powder and thermoplastic resin powder. The dried gel powder contains an ion exchange resin including a sulfonic acid group, and a nitrogen-containing chelating resin.