Exponential Pore Size Gradient Filter Media
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Solution Overview
Problem
Current filter media technologies do not effectively optimize pore size gradients to enhance filtration performance characteristics such as dust holding capacity and efficiency across the thickness of the media.
Innovation Solution
A filter media with a gradient in mean pore size represented by an exponential function across its thickness, determined using a least squares linear regression model, which provides a strong goodness of fit and enhances filtration properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform pore size structure is used in filter media, then the manufacturing process is simple, but the filtration performance (dust holding capacity and efficiency) is not optimized
Solution Approach 1:
The patent applies local quality by creating a pore size gradient where different regions of the filter media have different pore sizes. The upstream portion has larger pores for higher flow capacity, while the downstream portion has smaller pores for higher filtration efficiency, allowing each region to perform its specific function optimally
Solution Approach 2:
The patent changes the pore size parameter continuously across the thickness of the filter media using an exponential gradient function. This parameter change optimizes the balance between pressure drop and filtration efficiency by transitioning from larger pores at the inlet to smaller pores at the outlet
2Reliability
If multiple layers with different pore sizes are stacked, then filtration efficiency can be improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent segments the filter media into an upstream portion and a downstream portion with distinct pore size characteristics. This segmentation allows each portion to be optimized for its specific function (flow capacity vs. filtration efficiency) while maintaining a relatively simple single-layer structure
Solution Approach 2:
Instead of stacking multiple layers in the thickness direction, the patent creates a pore size gradient within the thickness direction itself. This dimensional approach achieves multi-layer-like performance through a continuous or discrete gradient in pore size across the media thickness
3Duration of action of moving object
If the pore size gradient is not optimized, then the manufacturing process is simpler, but the dust holding capacity and filter lifetime are reduced
Solution Approach 1:
The patent establishes a predetermined pore size gradient profile (exponential function with specific parameters) during the manufacturing process. This preliminary establishment of the optimal gradient ensures that the filter media achieves maximum dust holding capacity and extended lifetime from the outset, rather than requiring post-manufacturing adjustments
Data Source
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AI summary
Filter media having a gradient in a property and methods associated with such media are provided. In some embodiments, a filter media may have a gradient in mean pore size. The gradient in mean pore size may be across at least a portion of the thickness of the filter media. In some embodiments, the gradient can be represented by an exponential function. The exponential gradient in mean pore size may impart desirable properties to the filter media including enhanced filtration properties (e.g., relatively high dust holding capacity and efficiency), amongst other benefits. The filter media may be particularly well-suited for applications that involve filtering liquids (e.g., hydraulics, fuel, lube, water), though the media may also be used in other applications.