Layered Slurry Filter Element for Clog-Resistant Flow Paths
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Solution Overview
Problem
Existing filters for high-viscosity and high-solid-content slurry liquids, such as those used in lithium-ion battery electrode production, suffer from clogging and reduced flowability, leading to a shortened lifespan due to inadequate maintenance of flow paths.
Innovation Solution
A filter element composed of alternately layered nets and non-woven fabrics, with fibers extending in different directions and protrusions on the non-woven fabric surfaces, ensuring that protrusions do not obstruct the flow path by maintaining a gap between the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If particles are collected by the filter to perform filtration function, then filtration is achieved, but filter clogging occurs and flowability deteriorates, reducing filter life
Solution Approach 1:
The filter element is divided into multiple filtration layers with different pore sizes arranged in sequence. Coarse particles are captured by larger pore layers first, then finer particles are captured by subsequent smaller pore layers, distributing the filtration load and preventing any single layer from clogging quickly.
Solution Approach 2:
The filter uses porous structures with controlled pore sizes and distributions. The porous layers allow liquid to pass through while capturing particles, and the specific pore size design enables maintained flow paths even during particle collection, preventing complete blockage.
2Object-affected harmful factors
If filter mesh structure is used to prevent clogging, then initial clogging is reduced, but flow paths in filter layers are not maintained, limiting filter life extension
Solution Approach 1:
The filter is segmented into multiple functional layers including porous filtration layers and flow path maintenance layers. This segmentation allows different regions to perform different functions: some layers capture particles while other layers maintain open flow channels, addressing both clogging prevention and flow path maintenance.
Solution Approach 2:
Flow path maintenance layers act as intermediaries between the particle-capturing filtration layers and the liquid flow. These intermediary layers prevent direct contact between captured particles and the main flow paths, maintaining flowability while allowing filtration to occur.
3Productivity
If slurry liquid with high viscosity and high solid content is filtered, then electrode paste production is enabled, but flow resistance is high and filter life is shortened
Solution Approach 1:
The filtration system is segmented into multiple layers with progressively smaller pore sizes, allowing high-solid-content slurry to be processed efficiently. Each layer handles a portion of the particle capture load, preventing any single layer from becoming completely blocked by the high solid content material.
Solution Approach 2:
Porous materials with optimized pore size distributions are used to handle high-viscosity slurry. The porous structure provides multiple flow paths that remain open even under high viscosity conditions, maintaining flowability while capturing particles from the electrode paste slurry.
Data Source
AI summary
A long-life in filters is required as filter members for slurry liquid having high-viscosity and high-solid-content ratio. It is provided to solve the problem, the filter element for filtering slurry liquid, wherein nets and non-woven fabrics are alternately layered, wherein each of the nets has first fibers parallelly extending in one direction and second fibers parallelly extending in a direction angled to the one direction and contacting sides of the first fibers, wherein the first and second fibers forms mesh-pores at portions surrounded by the first and second fibers, wherein each of the non-woven fabrics has protrusions on surfaces of the each of the non-woven fabrics in a thickness-direction, the protrusions formed to repeatedly come out on the surfaces of the each of the non-woven fabrics in a surface-direction of the each of the non-woven fabrics.