Fiber Web With Spacer Particulate For Low Pressure Drop Filtration
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Solution Overview
Problem
Current filtration media face challenges in achieving high filtration efficiency while maintaining low pressure drop and extended lifetime, particularly in applications requiring the removal of sub-micron particles, as they often result in increased pressure drop and mechanical failure due to particulate accumulation.
Innovation Solution
A fiber web structure incorporating a continuous fine fiber phase with a dispersed particulate spacer means, which reduces solidity and increases the depth of the fiber web without adding more polymer or fibers, enhancing filtration properties such as resistance to pressure drop, Figure of Merit, and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional filtration media are used to achieve high filtration efficiency, then sub-micron particles can be captured, but pressure drop increases and lifetime is reduced due to particulate accumulation
Solution Approach 1:
The patent applies local quality by creating regions of different fiber densities within the filtration media. The media contains both dense regions for particle capture and sparse regions for fluid flow, with the fiber distribution varying locally to optimize both filtration efficiency and pressure drop characteristics
Solution Approach 2:
The patent transitions from traditional two-dimensional surface filtering to three-dimensional depth filtration by creating a volumetric structure with fibers distributed throughout the media thickness. This allows particles to be captured throughout the depth of the media rather than just at the surface, improving efficiency while maintaining flow paths
2Measurement precision
If traditional filtration media are used to achieve high filtration efficiency, then sub-micron particles can be captured, but lifetime is reduced due to mechanical failure from particulate accumulation
Solution Approach 1:
The patent creates local variations in fiber density and distribution throughout the media structure, providing regions that can accommodate particle accumulation without compromising the overall structural integrity. This local heterogeneity allows the media to handle particulate loads more effectively over extended periods
Solution Approach 2:
The patent employs a composite structure combining fibers of different diameters, materials, or properties within the same filtration media. This composite approach creates a more robust structure that resists mechanical failure from particle accumulation while maintaining high filtration efficiency
3Measurement precision
If fiber web depth is increased to improve filtration efficiency, then more particles can be captured, but the amount of polymer and fibers must be increased
Solution Approach 1:
The patent exploits the third dimension (depth) by creating a volumetric fiber distribution rather than a planar structure. This allows the media to achieve high filtration efficiency through increased path length and capture volume without proportionally increasing the total fiber mass, as the fibers are distributed throughout the available volume
Solution Approach 2:
The patent changes the structural parameters of the fiber web, including fiber diameter distribution, porosity gradients, and spatial arrangement, to optimize the relationship between filtration efficiency and material quantity. By adjusting these parameters, the media achieves high efficiency with reduced polymer content
Data Source
AI summary
A web can comprise a substantially continuous fiber mass and a separation means dispersed into the fiber. The web having a preferred thickness resulting from forming a polymer material and a particulate into a fine fiber layer can have a variety of end uses. A filtration media can include a structure comprising such a web of fine fiber and a substantial volume of particulate embodiment of the separation means. The resulting fine fiber structure provides an improved filtration medium having substantial depth, thickness, and a layered structure. The improved properties of the web results from inclusion of the separation or spacer particulate.