Monolithic Filtration Element With Internal Obstacles
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Solution Overview
Problem
Filtration membranes with traditional tubular geometries face clogging issues due to particle adsorption and pore blocking, leading to reduced performance and increased operational costs, as existing solutions for turbulence induction are complex and stress the material, limiting their effectiveness and scalability.
Innovation Solution
The development of monolithic filtration elements with a three-dimensional porous support structure featuring internal obstacles that generate turbulence and shear stresses, reducing clogging by forcing fluid bypass and maintaining material integrity, combined with an additive manufacturing method for producing these complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional tubular geometries with smooth rectilinear channels are used, then manufacturing is simple, but clogging occurs due to particle adsorption and pore blocking
Solution Approach 1:
The patent applies local quality by introducing obstacles at specific locations within the channel rather than changing the entire channel geometry. These obstacles create localized turbulence zones and shear stress regions that prevent particle deposition, while the rest of the channel maintains its simple smooth geometry for easy manufacturing. The obstacles are strategically positioned to maximize their anti-clogging effect without complicating the overall structure.
Solution Approach 2:
The patent transitions from traditional two-dimensional smooth channel surfaces to three-dimensional obstacles with varying heights and shapes protruding into the channel. This dimensional change creates complex flow patterns, eddies, and recirculation zones that enhance shear stress and prevent particle accumulation, while the obstacles themselves are integrated into the monolithic support structure.
2Reliability
If turbulence-inducing devices are added to reduce clogging, then clogging resistance improves, but device complexity and material stress increase
Solution Approach 1:
The patent merges the turbulence-inducing function directly into the support structure by integrating obstacles as an inherent part of the monolithic element. This eliminates the need for separate, removable turbulence devices and simplifies the overall structure. The obstacles are formed simultaneously with the support during manufacturing, creating a unified component that reduces complexity while maintaining clogging resistance.
Solution Approach 2:
The obstacles within the channel serve dual functions: they structurally define the channel geometry and simultaneously generate the turbulence and shear stress needed to prevent clogging. The flow itself interacts with these self-contained features to create the necessary hydrodynamic conditions, eliminating the need for external control mechanisms or additional moving parts.
3Reliability
If complex geometries are manufactured by traditional methods, then turbulence can be induced, but manufacturing precision and material integrity are compromised
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (extrusion, machining, sintering) with additive manufacturing technology. This substitution enables the precise creation of complex three-dimensional obstacle geometries that would be difficult or impossible to achieve with conventional methods. The layer-by-layer deposition process allows for high geometric precision and intricate details while maintaining material integrity throughout the structure.
Solution Approach 2:
The patent utilizes parameter changes in the additive manufacturing process, such as layer thickness, deposition rate, and sintering temperature, to optimize both the geometric precision of the obstacles and the mechanical properties of the monolithic support. By carefully controlling these parameters, the manufacturing process achieves high precision complex geometries without compromising material integrity or structural strength.
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 solution effectively reduces or eliminates clogging phenomena, enhancing filtration efficiency and surface area utilization while maintaining mechanical resistance, allowing for scalable production of multichannel elements with improved flow rates and reliability.
Implementation Method 1
obstacles (9) starting from the internal walls (31) channels and capable of generating disturbances in the flow and shear forces of sufficient amplitude to cause recirculations to appear
Implementation Method 2
capable of generating disturbances in the flow and shear forces of sufficient amplitude to cause recirculations to appear
Implementation Method 3
a rectilinear rigid porous support (2) of three-dimensional structure inside which at least one channel (3) is arranged for the circulation of a fluid medium to be treated with a view to recovering a filtrate on the exterior surface of the support
Implementation Method 4
A membrane constitutes a selective barrier and allows, under the action of a transfer force, the passage or stopping of certain components of the medium to be treated. The passage or stopping of the components results from their size in relation to the size of the pores of the membrane which then behaves like a filter.
Implementation Method 5
The method consists of producing the three-dimensional structure of the support by consolidating, in a selective and successive manner, a series of material layers
Data Source
Figure 1A~2
Figure 3A~5B
Figure 6A~8
AI summary
The invention relates to a one-piece element for separating, via tangential flow, a fluid medium to be treated. Said element comprises a rigid, porous, rectilinear holder (2) having a three-dimensional structure, inside which at least one channel (3) is provided for allowing the flow of the fluid medium to be treated with a view to recovering a filtrate on the peripheral surface of the holder. The rigid, porous, one-piece holder (2) comprises, projecting from the inner wall of the channel(s), obstacles (9) to the flow of the fluid to be filtered that are identical in terms of material and porous texture with regards to the holder, there being no break in the material or porous texture between the holder and the obstacles.