Filtration Membrane With Multi-Level Macroscopic Cavities
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Solution Overview
Problem
Current microfiltration membranes face challenges in enhancing total throughput and flow rate without increasing the filter material's surface area, often resulting in higher hydrodynamic resistance and reduced flow rates due to particulate deposition and clogging, especially in applications like food and beverage filtration and biopharmaceutical processes.
Innovation Solution
A micro-porous filtration membrane with multi-level macroscopic cavities extending from the first main surface into the porous membrane, featuring irregularly arranged cavities with varying penetration depths and diameters, which increase the non-filtrate surface area and accessibility of sub-surface pores, reducing flow resistance and enhancing total throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filter area is enlarged to increase total throughput, then the dirt holding capacity increases, but the filter device size and manufacturing costs increase
Solution Approach 1:
The invention transitions from a two-dimensional flat filter surface to a three-dimensional structure by creating macroscopic cavities that extend into the membrane thickness. This vertical dimensionality change increases the effective filtration surface area within the same device footprint, resolving the contradiction between throughput and device size
Solution Approach 2:
The macroscopic cavities are nested within the membrane structure itself, creating internal filtration surfaces that are contained within the existing device boundaries. This nesting approach increases functional surface area without requiring external expansion of the device
2Productivity
If more filter material is arranged compacted in the same device size to increase throughput, then the filter area is maintained, but the hydrodynamic resistance increases and flow rate decreases
Solution Approach 1:
By creating cavities that extend vertically into the membrane, the invention provides additional filtration pathways in the third dimension. This reduces the compaction density in the horizontal plane, maintaining lower hydrodynamic resistance while increasing total filtration capacity
Solution Approach 2:
The cavities are strategically positioned and sized to create localized high-flow channels within the membrane structure. This local optimization allows different regions of the membrane to handle flow differently, reducing overall hydrodynamic resistance while maintaining high throughput
3Productivity
If the filter area is enlarged to increase flow rate, then the flow performance improves, but the amount of filter material and manufacturing costs increase
Solution Approach 1:
The invention creates additional flow pathways by extending the filtration surface vertically through cavity formation. This three-dimensional approach increases the effective flow capacity without requiring proportional increases in material quantity, as the same material is utilized more efficiently in multiple spatial dimensions
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 membrane achieves improved total throughput and flow rate by creating a three-dimensional surface with voids, increasing cavity density and reducing hydrodynamic resistance, thus providing more efficient filtration without the need for larger filter devices.
Implementation Method 1
Filtration is understood to mean a method for separating solid particles or molecules from a fluid (i.e. liquids or gases)... a porous medium, such as a filter paper or membrane, is perfused by the continuous phase
Implementation Method 2
Porous membranes are used mainly in the methods of ultrafiltration... Whether a particle or molecule is retained by ultrafiltration membranes depends, in addition to the operating conditions, in particular on its size and structure relative to the size and structure of the membrane pores
Implementation Method 3
increasing the non-filtrate surface area and accessibility of sub-surface pores, reducing flow resistance
Data Source
Figure 1~3
Figure 4(a)~5
Figure 6~7(e)
AI summary
The present invention relates to a micro-porous filtration membrane with performance enhancing multi-level macroscopic cavities as well as a method for producing the same.