Filter Material With Dual-Side Binder Systems For Viscous Liquid Filtration
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Solution Overview
Problem
Filter materials used in filter elements often fail to withstand high mechanical stresses, particularly when filtering highly viscous liquids, leading to reduced filtration surface area and increased pressure differential, and require additional thermoplastic polymers or films for thermal welding.
Innovation Solution
A filter material is developed with a pre-crosslinked binder system on one side and a crosslinkable binder system on the other, allowing for improved deformability and thermal weldability without the need for additional thermoplastic polymers or films, enabling effective filtration of highly viscous liquids and maintaining a lower initial pressure differential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the filter material is impregnated with a thermally curable binder to increase rigidity, then the filter material can withstand higher mechanical stresses, but the folds are pressed against one another during filtration of highly viscous liquids, reducing filtration surface area and increasing pressure differential
Solution Approach 1:
The patent changes the crosslinking degree parameter of the binder system from complete (100%) to partial (5-50%), creating a binder that is crosslinked enough to provide rigidity but not so much that it causes excessive fold compression. This parameter optimization resolves the contradiction between needing rigidity for mechanical strength and maintaining fold separation for filtration surface area.
2Strength
If the filter material is made more rigid through impregnation, then it can withstand filtration pressure, but thermal welding becomes difficult without additional thermoplastic polymers or films
Solution Approach 1:
The patent applies different qualities to different sides of the filter material: one side has a thermally curable binder for rigidity, while the other side has a thermoplastic binder for weldability. This local differentiation allows the material to simultaneously achieve mechanical strength and ease of thermal welding without requiring additional polymers or films.
3Area of stationary object
If narrow and deep folds are created to maximize filtration surface area, then service life increases and pressure differential decreases, but the folds require high rigidity to withstand mechanical stresses
Solution Approach 1:
The patent optimizes the crosslinking degree parameter of the binder to a specific range (5-50%) that provides sufficient rigidity to support narrow and deep folds while maintaining their structural integrity under mechanical stress. This parameter control enables the creation of high-surface-area folds without excessive material stiffness.
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 material exhibits improved thermal sealability and significantly lower initial pressure differential when filtering highly viscous liquids, while maintaining robustness and allowing for easy folding and embossing, thus extending the service life and maintaining filtration efficiency.
Implementation Method 1
the filter material is impregnated with a binder, which thermally cures after folding and embossing
Implementation Method 2
by welding, preferably using ultrasound
Data Source
AI summary
The invention relates to a filter material comprising a carrier material that is impregnated on one side with a thermally pre-crosslinked binder system (VB) and on the other side with a thermally crosslinkable but un-crosslinked binder system (UB). The filter material is characterised by improved deformability and a very good level of heat sealability, particularly using ultrasound, and a low pressure differential particularly when filtering high-viscosity liquids.