Particle-Loaded Meltblown Fiber Web for Liquid Filtration

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Solution Overview

Problem

Existing water filtration systems face challenges in providing compact, high-capacity filtration with minimal pressure drop and reduced degradation of filter media, especially when using thermally sensitive sorbent materials, and have limited service life and efficiency in removing contaminants and sediments.

Innovation Solution

The use of particle-loaded meltblown fiber webs with self-supporting nonwoven polymeric fibers and high loadings of sorbent particles, which are enmeshed within the fibers to form a porous article housed in a liquid-impermeable structure, allowing for efficient filtration with low resistance to fluid flow and improved sediment retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If carbon block technology is used to increase sorptive material loading, then filtration capacity is improved, but pressure drop across the block increases

Engineering Contradiction:

Improvesorptive material loadingVSAvoidpressure drop

Core Design Contradiction:

Quantity of substanceVSStress or pressure

Solution Approach 1:

The patent uses composite blocks made from combinations of sorbent materials (such as adsorbent activated carbon) and polymeric binders (such as polyethylene) that have been sintered together under conditions of heat and pressure. This composite structure allows high loading of sorptive materials while maintaining low pressure drop through the optimized porous structure.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention employs porous composite blocks with controlled pore structures that allow fluid flow while providing high surface area for adsorption. The porous structure enables high sorptive material loading without proportionally increasing pressure drop, as the pores provide flow pathways through the dense sorbent material.

Inventive Principle:

Principle #31Porous materials

2Strength

If carbon blocks are exposed to heat and pressure during manufacturing, then block structure is formed, but material selection is limited due to thermal degradation

Engineering Contradiction:

Improveblock structure integrityVSAvoidmaterial selection range

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent employs supercritical carbon dioxide as a processing medium that allows formation of dense, mechanically strong blocks without exposing thermally sensitive materials to degrading temperatures. By changing the processing parameters from conventional heat/pressure to supercritical CO2 conditions, the invention enables use of materials like ion exchange resins that would otherwise be precluded from carbon block technology.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces conventional thermal-mechanical sintering processes with a supercritical fluid-based consolidation process. This substitution eliminates the need for high temperature exposure during block formation, thereby preserving the integrity of thermally sensitive sorbent materials while still achieving strong block structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Quantity of substance

If loose bed carbon particles are used for filtration, then sorption capacity is provided, but particle shedding occurs

Engineering Contradiction:

Improvesorbent material capacityVSAvoidparticle shedding

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent embeds loose carbon particles within a polymeric binder matrix to form composite blocks. This composite structure provides the sorption capacity of loose particles while preventing particle shedding through the binding matrix. The polyethylene binder holds the carbon particles in place while allowing fluid to pass through and contact the sorbent surfaces.

Inventive Principle:

Principle #40Composite materials

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

This solution enables high-capacity filtration with low pressure drop, extended service life, and effective removal of contaminants and sediments, including thermally sensitive materials, while maintaining a compact design suitable for whole-house filtration systems.

Implementation Method 1

a porous article comprising a web of self-supporting nonwoven polymeric fibers and a plurality of sorbent particles enmeshed in the web

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

sorbent particles enmeshed in the web

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 3

an inlet in fluid communication with the first surface; and an outlet in fluid communication with the second surface

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS7828969B2Liquid filtration systems

Publication Date: 2010.11.09 SOLVENTUM INTELLECTUAL PROPERTIES CO

AI summary

Provided are filter elements and methods of making and using the same where the filter elements are suitable for liquid filtration and contain particle-loaded meltblown fiber webs. A filter element comprises: a porous article comprising a web of self-supporting nonwoven polymeric fibers and a plurality of sorbent particles enmeshed in the web, the article comprising a first surface and a second surface; a liquid-impermeable housing surrounding the porous article; an inlet in fluid communication with the first surface; and an outlet in fluid communication with the second surface. Spiral-wound webs, web-covered blocks, and stacked disks of webs are also provided.