Flake Powder Coated Metal Filter for Filtration Permeability Trade-off
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Solution Overview
Problem
Conventional filters for semiconductor and gas applications face challenges in achieving a balance between high filtration rate and permeability, often resulting in reduced efficiency and increased load on filtration devices due to limitations in pore size and material properties.
Innovation Solution
A filter with a porous metal support and a metal coating layer formed by bonding flake-shaped metal powders, creating a three-dimensional pore structure that enhances both filtration rate and permeability, while reducing the thickness and material requirements of the coating layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pore size is reduced to increase the filtration rate, then the filtration rate is improved, but the permeability decreases
Solution Approach 1:
The patent employs a porous substrate as the base structure, providing a three-dimensional pore network that allows fluid penetration while supporting the coating layer. The porous structure maintains permeability while enabling the formation of a complex flow channel through the coating layer, resolving the contradiction between filtration rate and permeability.
Solution Approach 2:
The patent creates a composite structure combining a porous substrate with a coating layer formed from flake-shaped metal powders. This composite architecture allows the substrate to provide permeability while the coating layer creates complicated flow channels that enhance filtration rate without significantly reducing overall permeability.
2Quantity of substance
If the pore size is increased to increase the permeability, then the permeability is improved, but the filtration rate is lowered
Solution Approach 1:
The patent applies different functional characteristics to different regions: the porous substrate provides permeability with larger pores, while the coating layer with flake-shaped powders creates localized complicated flow channels that enhance filtration. This local differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The patent transitions from a simple single-layer structure to a multi-layer composite structure, adding the dimension of the coating layer on top of the porous substrate. This additional dimension enables the creation of complicated flow channels that improve filtration rate while the substrate maintains permeability.
3Productivity
If a coating layer is added to improve filtration rate, then the filtration rate is improved, but the device complexity increases
Solution Approach 1:
The porous substrate provides a pre-established three-dimensional pore structure that simplifies the overall device architecture while supporting the coating layer. This porous backbone reduces the complexity that would otherwise result from adding a coating layer, as the substrate already provides the necessary structural framework.
Solution Approach 2:
The composite structure of porous substrate plus coating layer is presented as an integrated solution rather than separate components. The coating layer is formed directly on the porous substrate, creating a unified structure that improves filtration rate without proportionally increasing device complexity.
4Productivity
If the coating layer thickness is increased to improve filtration rate, then the filtration rate is improved, but the permeability decreases
Solution Approach 1:
The porous substrate provides a three-dimensional pore network that maintains permeability even when the coating layer is relatively thick. The substrate's porous structure acts as a permeability buffer, allowing fluid to penetrate through the coating layer without requiring the coating to be extremely thin.
Solution Approach 2:
The flake-shaped metal powders create curved and irregular flow channels within the coating layer, as opposed to straight linear paths. This curvature increases the path length and complexity of fluid flow, enhancing filtration rate while the overall coating thickness remains manageable to preserve permeability.
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 achieves improved filtration rate and permeability by forming a complex flow channel with flake-shaped powders, reducing the need for additional layers and minimizing device load, while maintaining high efficiency and mechanical properties.
Implementation Method 1
forming a coating layer by bonding flake-shaped metal powders
Implementation Method 2
the permeability that is the degree through which the fluid including the filtration target permeates the filter
Data Source
AI summary
It is an object of the present invention to provide a filter having excellent filtration rate and excellent permeability and a method for producing the same. To achieve the above object, the present invention provides a filter comprising a porous metal support having the first pore size; and a metal coating layer formed on the support and having the second pore size smaller than the first pore size, wherein the coating layer has a three-dimensional pore structure by bonding flake-shaped metal powders. The present invention also provides a method for producing the filter. According to the present invention, as the flake-shaped second powders form a coating layer, the porosity increases and the permeability increases, and as the flow channel becomes more complicated, the filtration rate also increases.