Multi-Layer Filter for Slurry Filtration
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Solution Overview
Problem
Conventional filters face challenges in filtering high concentration fluids, leading to powder aggregation and clogging, with short filtration life and poor flowability, especially when dealing with viscous fluids and high solids content.
Innovation Solution
A filter configuration with a base material layer, a filtration layer, and a skin layer, where the filtration layer is formed by laminating through-air nonwoven fabric and a net without thermocompression bonding, creating a moderate gap for improved flowability and preventing powder aggregation, with specific fiber diameters and pore diameters optimized for long filtration life and high classification performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the solids content is highly concentrated to achieve volume reduction and shorter drying time, then the filtration efficiency is improved, but the fluid flowability deteriorates and powder aggregation occurs causing filter clogging
Solution Approach 1:
The filter is divided into multiple layers with different functions: a prefiltration layer for coarse particles, a microfiltration layer for fine particles, and a support layer for structural integrity. This segmentation allows each layer to handle specific aspects of the concentrated slurry filtration, preventing overall clogging while maintaining high solids content processing capability
Solution Approach 2:
Different regions of the filter have different fiber diameters and pore sizes optimized for their specific functions. The prefiltration layer uses larger fibers for coarse filtration, while the microfiltration layer uses finer fibers for fine particle capture. This local optimization allows the filter to handle concentrated slurries without uniform clogging across the entire structure
2Duration of action of stationary object
If a nonwoven fiber aggregate with thinned fiber diameter in the filtration direction is used to improve filtration life, then the microfiltration performance is enhanced, but the production cost increases due to special spinning conditions
Solution Approach 1:
Instead of creating a single complex nonwoven fabric with gradient fiber diameters, the invention segments the filtration function into separate layers: a prefiltration layer with coarser fibers and a microfiltration layer with finer fibers. This segmentation achieves the same filtration life extension without requiring complex gradient spinning processes, reducing manufacturing cost
Solution Approach 2:
The prefiltration layer acts as an intermediary between the incoming concentrated slurry and the microfiltration layer. It captures larger particles first, preventing them from reaching and clogging the finer microfiltration layer, thereby extending the overall filtration life without requiring the microfiltration layer to handle all particle sizes alone
3Device complexity
If a conventional cartridge filter is used for high concentration slurry, then the filtration structure is simple, but powder aggregation occurs causing apparent particle diameter increase and filter clogging
Solution Approach 1:
The filter is segmented into multiple functional layers that work together to prevent powder aggregation. The prefiltration layer captures larger particles, reducing their ability to act as nucleation sites for aggregation, while the microfiltration layer captures finer particles. This segmented approach maintains reliable filtration performance for high concentration slurries without requiring overly complex structures
Solution Approach 2:
The filter uses a composite structure combining different nonwoven fabric types with distinct fiber diameter distributions. The prefiltration layer uses coarser nonwoven fabric while the microfiltration layer uses finer nonwoven fabric. This composite material approach prevents powder aggregation by distributing particles across different size ranges in separate layers, maintaining filtration reliability for concentrated slurries
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 effectively prevents powder aggregation, extends filtration life, and maintains high classification performance even with viscous fluids, ensuring efficient filtration and capturing efficiency.
Implementation Method 1
a filtration layer, as a layer formed by a laminate prepared by laminating at least a through-air nonwoven fabric and a net
Implementation Method 2
a base material layer, as a layer formed by a nonwoven fabric being wound in a multiple manner, and subjected to thermocompression bonding
Data Source
AI summary
Shown is a filter in which powder aggregation (bridge) is hard to occur, and a time until a rise of differential pressure is caused is long, more specifically, a filtration life is long. The filter has a base material layer, a filtration layer and a skin layer, in which the base material layer is a layer formed by a nonwoven fabric being wound in a multiple manner, and subjected to the thermocompression bonding, the filtration layer is a layer formed by a laminate prepared by laminating at least a through-air nonwoven fabric and a net, being wound in a multiple manner, and subjected to no thermocompression bonding, the skin layer is a layer including a nonwoven fabric, and a mean pore diameter of the nonwoven fabric composing the base material layer and the skin layer is larger than a mean pore diameter of the through-air nonwoven fabric composing the filtration layer.