Multi-layer Fiber Filter with Embedded Nanofibers

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Solution Overview

Problem

Conventional filters face challenges in achieving high filtration efficiency with low pressure drop and abrasion resistance, particularly in ink jet printer applications, where they are prone to damage from frictional forces and require complex manufacturing processes for installation.

Innovation Solution

A multi-layer bonded fiber structure comprising polymeric microfiber layers with nanofibers embedded between them, providing tortuous fluid paths and enhanced filtration efficiency while being die-cuttable and ultrasonically bondable to plastic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional filter media with larger pore sizes are used, then pressure drop is reduced, but filtration efficiency deteriorates

Engineering Contradiction:

Improvepressure dropVSAvoidfiltration efficiency

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent combines nanofibers (providing fine filtration) with microfibers (providing structural support and low pressure drop) to create a composite filter media that achieves both high filtration efficiency and low pressure drop simultaneously, resolving the trade-off between these two parameters

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent creates regions with different fiber densities and pore sizes within the filter media - denser nanofiber regions for filtration and more open microfiber regions for fluid flow, allowing different zones to optimize for different functions

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If filter media thickness is increased to improve filtration efficiency, then pore size is reduced, but pressure drop increases

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidpressure drop

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

By using a composite of nanofibers and microfibers, the patent achieves high filtration efficiency in a thinner media structure, eliminating the need to increase thickness to improve filtration while maintaining low pressure drop characteristics

Inventive Principle:

Principle #40Composite materials

3Reliability

If stainless steel filters are used for abrasion resistance, then durability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveabrasion resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses polymeric fibers that can be thermally bonded, creating a filter that is easier and less expensive to manufacture than stainless steel filters, while still providing sufficient durability for the application

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the material parameters from metal to polymer, enabling different bonding and manufacturing methods (thermal bonding vs. complex mechanical assembly) that simplify the manufacturing process

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If polymeric fibers are used instead of metal, then ease of bonding is improved, but abrasion resistance deteriorates

Engineering Contradiction:

Improvebonding capabilityVSAvoidabrasion resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent creates a composite structure where microfibers provide abrasion resistance and nanofibers provide filtration capability, allowing the use of polymeric materials that can be thermally bonded while maintaining sufficient durability

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

The structure achieves high filtration efficiency with low pressure drop and improved abrasion resistance, facilitating easier installation and reduced manufacturing complexity, while protecting sensitive nanofiber components from frictional forces.

Implementation Method 1

The polymeric fibers of the first fiber layer have diameters greater than one micron and collectively define a first plurality of interconnected interstitial spaces providing tortuous fluid flow paths through the first fiber layer

Methodology Applied

Scientific EffectPhysical barrier filtration: Filter (physical)

Implementation Method 2

the pressure required to force the fluid (either liquid or gas) through the pores of the filter can become quite large

Methodology Applied

Scientific EffectPressure gradient-driven flow: Pressure Gradient

Data Source

PatentUS8939295B2Multi-layer, fluid transmissive fiber structures containing nanofibers and a method of manufacturing such structures

Publication Date: 2015.01.27 POREX TECHNOLOGIES CORP

AI summary

A multi-layer, fluid transmissive structure is provided that comprises first and second fiber layers each comprising a plurality of polymeric fibers bonded to each other at spaced apart contact points. The polymeric fibers of these fiber layers have diameters greater than one micron and collectively define interconnected interstitial spaces providing tortuous fluid flow paths through the first and second fiber layers. The structure also comprises a plurality of nanofibers disposed intermediate at least a portion of the first fiber layer and at least a portion of the second fiber layer.