Nanofiber Filter Media Depth Filtration

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Solution Overview

Problem

Filtration systems for internal combustion engines face challenges in achieving high particulate removal, low restriction, and long life while minimizing costs, particularly in engine air and diesel fuel filtration, where thin media relies on surface filtration that does not provide optimal dust holding capacity and filter life.

Innovation Solution

A composite filter media comprising a nanofiber layer with a geometric mean diameter of less than or equal to 0.5 μm, bonded to a substrate layer, with polymeric masses providing anchor points and a three-dimensional surface, enabling hybrid surface-depth filtration and increased media surface area within a defined volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If thin media is used to maximize media surface area in a defined filter volume, then the amount of media surface area available for contaminant removal increases, but dust holding capacity and filter life deteriorate due to reliance on surface filtration only

Engineering Contradiction:

Improvemedia surface areaVSAvoidfilter life

Core Design Contradiction:

Area of stationary objectVSDuration of action of stationary object

Solution Approach 1:

The patent transitions from two-dimensional surface filtration to three-dimensional depth filtration by creating a nanofiber layer with thickness of 1-100 μm. This allows contaminant capture throughout the volume of the media rather than just at the surface, enabling both high surface area density and extended filter life through depth filtration mechanisms.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent creates a composite structure combining nanofibers (1-100 μm thick) with a substrate layer. This composite material integrates the high surface area characteristics of thin nanofiber layers with the structural support and dust holding capacity of the substrate, resolving the contradiction between maximizing surface area and maintaining filter life.

Inventive Principle:

Principle #40Composite materials

2Duration of action of stationary object

If nanofiber layer thickness is increased to provide depth filtration, then dust holding capacity improves, but the amount of media that can be packaged in a defined filter volume decreases

Engineering Contradiction:

Improvedust holding capacityVSAvoidmedia surface area

Core Design Contradiction:

Duration of action of stationary objectVSArea of stationary object

Solution Approach 1:

The patent optimizes the nanofiber layer thickness parameter to a specific range of 1-100 μm, which is thick enough to provide depth filtration and dust holding capacity but thin enough to allow high media surface area density in a defined filter volume. This parameter optimization resolves the contradiction between depth filtration benefits and surface area packaging.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If conventional surface filtration is used in thin media, then filter design is simpler, but particulate removal efficiency and filter life are suboptimal

Engineering Contradiction:

Improvefilter design complexityVSAvoidparticulate removal efficiency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent segments the filtration function into two distinct layers: a nanofiber layer (1-100 μm thick) that performs depth filtration and contaminant capture, and a substrate layer that provides structural support. This segmentation enables hybrid surface-depth filtration that improves particulate removal efficiency while maintaining manageable design complexity.

Inventive Principle:

Principle #1Segmentation

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 composite filter media achieves improved particulate removal efficiency, extended filter life, and reduced pressure drop, while maintaining a thin profile, effectively addressing the limitations of conventional filtration systems by utilizing depth filtration in addition to surface filtration.

Implementation Method 1

A first set of embodiments relate to a composite filter media, comprising at least one nanofiber layer bonded to a substrate layer, the at least one nanofiber layer comprising a plurality of nanofibers having a geometric mean diameter of less than or equal to 0.5 μm

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

the at least one nanofiber layer further comprises polymeric masses having an area equivalent diameter of larger than 1 μm and covering 1-25% of media surface area

Methodology Applied

Scientific EffectHybrid surface-depth filtration:

Data Source

PatentUS11633682B2Nanofiber filter media for high performance applications

Publication Date: 2023.04.25 ATMUS FILTRATION IP INC

AI summary

Disclosed here is a composite filter media having at least one nanofiber layer bonded to a substrate layer, the at least one nanofiber layer optionally having a plurality of nanofibers having a geometric mean diameter of less than or equal to 0.5 μm, the at least one nanofiber layer having a thickness of about 1-100 μm.