Filter Composite Material with Drainage Fabric for Backflushing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional filter systems face issues with membrane clogging due to particle accumulation, leading to reduced filtration performance and potential damage from backflushing, which is inefficient and costly.
Innovation Solution
A filter composite material with a woven drainage fabric laminated between two filtration membranes, providing dynamic pressure stability above 0.15 bar, allowing for effective backflushing without membrane damage, and a method for producing this composite material using thermally cured loop-formingly knitted spacer fabrics and adhesive nets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional filter membranes are used for wastewater filtration, then filtration performance is initially good, but particle accumulation causes membrane clogging and reduced performance over time
Solution Approach 1:
The filter element is segmented into three functional layers: a support nonwoven layer, a filtration membrane layer, and a drainage structure layer. This segmentation allows each layer to perform its specific function - the support layer provides structural integrity, the filtration membrane captures particles, and the drainage structure prevents clogging by facilitating liquid flow, thereby maintaining filtration performance and extending maintenance intervals
Solution Approach 2:
The drainage structure is made from porous materials with controlled pore sizes that allow liquid to pass through while preventing particle accumulation. The porous structure enables efficient liquid drainage while maintaining filter integrity, reducing membrane clogging and extending the time between maintenance operations
2Ease of operation
If backflushing is performed to clean clogged membranes, then cleaning efficiency improves, but membrane damage occurs due to high pressure
Solution Approach 1:
The support nonwoven layer and drainage structure are positioned beforehand to cushion and distribute the pressure during backflushing operations. These protective layers absorb and distribute the mechanical stress, preventing direct high-pressure damage to the filtration membrane while still allowing effective cleaning to occur
Solution Approach 2:
The filter element uses a composite structure combining different materials with complementary properties: the support nonwoven provides mechanical strength, the filtration membrane provides selective permeability, and the drainage structure provides pressure distribution. This composite design enables effective backflushing while protecting the membrane from damage
3Stability of the object's composition
If the drainage structure is made from rigid plate material, then structural stability is improved, but flexibility and adaptability to pressure changes deteriorate
Solution Approach 1:
The drainage structure uses woven fabric material whose physical parameters (pore size, thread density, weave pattern) are optimized to provide both structural stability and pressure adaptability. The fabric's inherent flexibility allows it to adapt to pressure changes while maintaining sufficient structural integrity to support the filtration membrane and facilitate drainage
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 composite material enhances backflushability and durability, maintaining filtration performance while preventing membrane damage and clogging, allowing for longer intervals between maintenance and improved cleaning efficiency.
Implementation Method 1
a first adhesive net (12), which consists of a thermoplastic polymer, a woven drainage fabric (3), a second adhesive net (14) of a thermoplastic polymer
Implementation Method 2
bonding the woven drainage fabric (3) durably and face-touchingly to the filtration membranes (1, 5)
Data Source
AI summary
A filter composite material is provided that includes first and second filtration membranes and a drainage material arranged therebetween. The drainage material and the filtration membranes are laminated using adhesive nets. A flat filter element is made as a blank from the filter composite material and has a geometric shape adapted to the particular end use.