Hydrophobic filter medium
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Solution Overview
Problem
Existing filter media, particularly those made from hydrophilic cellulose-based paper, become less hydrophobic and more prone to water absorption when corrugated, leading to compromised filtration performance and structural integrity, while maintaining desirable properties like hydrophobicity and stiffness remains challenging.
Innovation Solution
Treating a nonwoven layer with a sizing agent and a hydrophobic, stiffening binder resin, followed by optional corrugation, to create a filter medium that maintains hydrophobicity and structural integrity even after corrugation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter media are made from hydrophilic cellulose-based paper, then the base paper provides good filtration properties, but the filter medium absorbs water readily and loses hydrophobicity when corrugated
Solution Approach 1:
The patent applies chemical treatment to change the surface properties of the cellulose paper from hydrophilic to hydrophobic. Specifically, hydrophobic agents (such as silanes, waxes, or fluorinated compounds) are applied to the paper surface, altering its chemical composition and surface energy, thereby reducing water absorption while maintaining filtration performance.
Solution Approach 2:
The patent creates a composite structure by combining hydrophilic cellulose base paper with hydrophobic coating layers or treated surfaces. This composite approach allows the bulk paper to provide mechanical strength and filtration porosity, while the hydrophobic surface layer prevents water absorption and maintains hydrophobicity even when corrugated.
2Strength
If the filter medium is corrugated to increase surface area and stiffness, then filtration efficiency and structural rigidity improve, but hydrophobicity is reduced and water absorption increases
Solution Approach 1:
The patent applies hydrophobic treatment to the paper surface before corrugation. This preliminary action ensures that the hydrophobic coating is already in place on the flat paper, and when the paper is subsequently corrugated, the coating remains intact and maintains hydrophobicity, preventing water absorption in the corrugated structure.
Solution Approach 2:
The patent modifies the surface chemistry parameters of the paper to achieve hydrophobicity that is maintained through the corrugation process. By controlling the surface energy and chemical composition, the paper retains its water-repelling properties even after mechanical deformation into corrugated shapes.
3Object-affected harmful factors
If hydrophobic agents are applied to base paper to achieve hydrophobicity, then water absorption is reduced, but the paper becomes more fragile and less rigid
Solution Approach 1:
The patent applies hydrophobic treatment selectively to the surface of the paper rather than throughout the bulk material. This local quality approach allows the surface to be hydrophobic (resisting water absorption) while the bulk paper retains its original mechanical strength and rigidity. The treatment is concentrated where water contact occurs, preserving the structural integrity of the base paper.
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 medium exhibits reduced water absorption and maintains filtration performance, structural integrity, and stiffness without the need for expensive additives, suitable for use in various filtration applications.
Implementation Method 1
the nonwoven layer having been treated with a sizing agent, and then treated with a hydrophobic, stiffening binder resin
Implementation Method 2
a hydrophobic, stiffening binder resin
Implementation Method 3
Filtration systems are used to remove undesirable materials such as particulates from liquids or gases by passing the liquid or gas through a filter medium
Data Source
AI summary
Herein is disclosed a filter medium comprising: a nonwoven layer, the nonwoven layer having been treated with a sizing agent, and then treated with a hydrophobic, stiffening binder resin, and then optionally corrugated. Also disclosed is a method of producing a filter medium. The filter medium may be a fuel filter, oil filter, air filter, or an electric discharge filter.