Nanofiber Composite Yarn Cartridge Filter for High-Efficiency Filtration
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Solution Overview
Problem
Conventional cartridge filters face limitations in achieving precise filtering due to uneven pore sizes and low mechanical strength, leading to reduced filtration efficiency and increased pressure loss, especially when using nanofibers in nonwoven fabrics or spiral wound configurations.
Innovation Solution
A multilayer cartridge filter using nanofiber composite fiber yarns, where nanofibers produced by electrospinning are laminated onto a porous substrate and wound around a core, maintaining an average pore size of less than 1 μm, enhancing filtration efficiency and filter life while increasing the filtration area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If conventional synthetic fibers and natural fibers with diameter of several to several tens of micrometers are used, then the filter structure is simple and easy to manufacture, but the filtration area cannot be increased within the same volume due to surface area limitation
Solution Approach 1:
The patent changes the fundamental parameter of fiber diameter from conventional several to tens of micrometers down to nanometer scale (less than 1 micrometer). This parameter change enables dramatically increased surface area within the same volume, thereby increasing filtration area without proportionally increasing filter size or complexity
Solution Approach 2:
The patent employs composite fiber structures combining different materials with distinct functions: hydrophobic fibers for oil separation, hydrophilic fibers for water filtration, and charged fibers for particle capture. This composite approach maximizes filtration area and efficiency while maintaining a compact filter structure
2Reliability
If nanofibers are used in nonwoven fabrics or spiral wound configurations, then the filtration efficiency is improved, but the mechanical strength is reduced and pressure loss increases
Solution Approach 1:
The patent applies local quality by assigning different properties to different regions and layers of the filter. The filter medium consists of multiple layers with varying fiber compositions, densities, and pore structures optimized for specific functions: pre-filtration, main filtration, and structural support. This localized optimization maintains mechanical strength in support layers while achieving high filtration efficiency in filtration layers
Solution Approach 2:
The patent uses composite materials combining nanofibers with appropriate binders and support structures. The composite structure provides both the high surface area needed for efficient filtration and the mechanical strength required for structural integrity, resolving the contradiction between filtration efficiency and mechanical strength
3Manufacturing precision
If uniform pore size is achieved to improve filtration precision, then the filtration efficiency is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent controls the pore size parameter through systematic variation of electrospinning process parameters including voltage, flow rate, and collector distance. This enables precise control of nanofiber diameter and packing density, achieving uniform pore sizes (less than 1 micrometer) while maintaining manufacturing feasibility through process optimization rather than complex equipment
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 enables precise filtering, improves filter efficiency, extends filter life, and increases the filtration area by utilizing the space between fiber yarns and nanofibers, thereby enhancing the performance and life of conventional filters.
Implementation Method 1
Research and development on the electrospinning method of producing a fiber with a limited diameter of less than 1 μm, which is the conventional fiber manufacturing method, such as melt spinning or solution spinning, by applying an electric field to the polymer melt.
Implementation Method 2
a nanofiber web which is produced by accumulating nanofibers produced by an electrospinning method is laminated on a porous nonwoven fabric
Data Source
AI summary
Provided is a cartridge filter using nanofiber composite fiber yarn, the cartridge filter including: a core having a plurality of holes through which a liquid passes; and a filter medium wound around the core to collect an object to be filtered contained in the liquid, wherein the filter medium comprises composite fiber yarn in which a nanofiber web which is produced by accumulating nanofibers produced by an electrospinning method is laminated to a porous nonwoven fabric, to thus provide excellent durability and improved filtration performance.