Multifunctional filter medium, and method and apparatus for manufacturing same
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Solution Overview
Problem
Current fiber-based filter systems for reducing dust, microorganisms, and toxic gases in vehicles increase energy consumption and generate process wastewater, while multistage systems with liquid chemical processes limit functional material utilization and increase pressure drop.
Innovation Solution
A multifunctional filter medium with photocatalyst particles and carbon nanotubes grown on the surface of fibers, manufactured using dry technology and a roll-to-roll system, which reduces energy consumption and maintains pressure drop levels similar to conventional systems while enhancing filtration efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multistage system with independent filter media is used to reduce dust, microorganisms, and toxic gases, then filtration efficiency is improved, but pressure drop increases
Solution Approach 1:
The patent combines multiple filtration functions (dust removal, microorganism removal, and toxic gas decomposition) into a single integrated filter medium. The filter medium includes photocatalyst particles with carbon nanotubes grown on their surfaces, which are attached to fiber surfaces. This merging eliminates the need for multiple separate filter stages, thereby maintaining filtration efficiency while reducing pressure drop.
Solution Approach 2:
The patent uses composite materials by combining photocatalyst particles, carbon nanotubes, and fiber materials into a single filter medium structure. The carbon nanotubes grown on photocatalyst particle surfaces create a hierarchical composite structure that provides both mechanical filtration and photocatalytic decomposition functions simultaneously, achieving high filtration efficiency with lower pressure drop.
2Adaptability or versatility
If liquid chemical process is used for manufacturing filter medium, then functional materials can be applied, but process wastewater is generated and functional materials are limited to inside fiber rather than surface
Solution Approach 1:
The patent replaces the liquid chemical impregnation process with a dry manufacturing process. Photocatalyst particles with carbon nanotubes grown on their surfaces are attached to fiber surfaces through a dry process, eliminating the need for liquid chemicals and preventing process wastewater generation. This substitution also enables functional materials to be effectively utilized on the surface rather than being limited to inside the fiber.
Solution Approach 2:
The photocatalyst particles with carbon nanotubes grown on their surfaces possess inherent functional properties that enable both filtration and photocatalytic decomposition without requiring additional liquid chemical treatments. The structure itself provides the necessary functionality, eliminating the need for harmful liquid chemical processes during manufacturing.
3Reliability
If high-density nanofiber is used to improve fine dust removal efficiency, then filtration performance is improved, but energy consumption increases
Solution Approach 1:
The patent creates a composite structure where carbon nanotubes are grown on photocatalyst particle surfaces, which are then attached to fiber surfaces. This hierarchical composite structure provides high fine dust removal efficiency through the carbon nanotube network while maintaining lower density compared to high-density nanofiber, thereby reducing energy consumption for filtration.
Solution Approach 2:
The patent applies functional materials locally on the fiber surface rather than using high-density nanofiber throughout. Photocatalyst particles with carbon nanotubes are attached to fiber surfaces, creating localized functional zones that provide high filtration efficiency for fine dust without requiring the entire filter medium to be high-density, thus reducing overall energy consumption.
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 medium effectively reduces fine dust, microorganisms, and toxic gases with reduced energy use and minimal pressure drop, achieving high productivity and efficient filtration performance as a single filter medium.
Implementation Method 1
photocatalyst particles on surfaces of which carbon nanotubes are grown. The photocatalyst particles adhere to a surface of the fiber
Implementation Method 2
the fiber may be utilized as fiber having micropores and mesopores efficient for adsorption of harmful gases
Implementation Method 3
the fiber may be utilized as fiber having micropores and mesopores efficient for adsorption of harmful gases
Implementation Method 4
porous fiber includes pores having a predetermined size and shape, thereby exhibiting high efficiency for removal of fine dust, harmful microorganisms, and toxic gases
Data Source
AI summary
The present application relates to a multifunctional filter medium and a method of manufacturing the same. The multifunctional filter medium of the present application is capable of significantly reducing fine dust, harmful microorganisms, and toxic gases and reducing a pressure decrease during filtration due to exclusion of high-density nanofiber, thereby minimizing energy required for filtration and exhibiting sufficient filtration performance as a single filter medium.