Nanofiber Filter Wrap Without Substrate
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Solution Overview
Problem
Existing nanofiber filter media are prone to clogging, have limited tensile strength, and require deposition on a substrate, which restricts their application and efficiency.
Innovation Solution
The development of nanofiber filter media formed from elongate flexible strips of film with tuned arrays of nanofibers, which are wound or folded to create a filter element with inter-layer spaces for fluid flow, allowing for optimal exploitation of electrostatic properties without reliance on a rigid substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nanofibers are deposited on a porous substrate to form filter media, then filtering efficiency is improved, but the filter media becomes dependent on substrate support and prone to delamination
Solution Approach 1:
The patent extracts and eliminates the substrate component from the traditional filter media structure. By using a non-woven fabric formed entirely from nanofibers without requiring substrate support, the invention removes the dependency on external substrates while maintaining filtering functionality through the self-supporting properties of the nanofiber network.
Solution Approach 2:
The patent creates a composite structure where nanofibers are combined to form a self-supporting non-woven fabric. The composite nature of the nanofiber network provides both structural integrity and filtering capability, eliminating the need for separate substrate support while maintaining high filtering efficiency.
2Reliability
If fine fibers are used to provide filtering of small particles, then filtering efficiency is improved, but the filter media becomes more rapid loading and difficult to handle
Solution Approach 1:
The patent employs a flexible non-woven fabric structure made from nanofibers that maintains thinness for high filtering efficiency while providing sufficient mechanical strength and flexibility for handling. The fabric's flexible nature allows it to be manipulated and installed without requiring rigid substrate support.
3Reliability
If nanofibers are formed into non-woven mats to achieve high surface-to-volume ratio, then filtering ability is improved, but physical strength is reduced and handling becomes impractical
Solution Approach 1:
The patent creates a flexible non-woven fabric from nanofibers that achieves high surface-to-volume ratio for enhanced filtering while developing sufficient physical strength through the collective structure of the fabric. The flexible film form allows the nanofibers to maintain their high surface area characteristics while providing handleability and structural integrity.
4Reliability
If electrospinning is used to produce nanofibers, then filtering properties are improved, but production rate is low and environmental friendliness is reduced
Solution Approach 1:
The patent changes the fundamental parameters of nanofiber production by moving away from electrospinning to alternative methods such as electrohydrodynamic jetting or direct extrusion. These parameter changes enable higher production rates while maintaining the filtering properties of nanofibers, and eliminate the need for harmful solvents and high voltages associated with traditional electrospinning.
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 proposed solution enhances the collection efficiency and reduces clogging of nanofiber filters, allowing them to withstand tensile loading and be handled independently of a substrate, while maintaining high filtering capabilities.
Implementation Method 1
In addition to filtering mechanisms, on the molecular level, fibrous materials also trap contaminants with electrostatic forces, including ionic bonding, hydrogen bonding, and Van der Waals forces.
Implementation Method 2
In addition to filtering mechanisms, on the molecular level, fibrous materials also trap contaminants with electrostatic forces, including ionic bonding, hydrogen bonding, and Van der Waals forces.
Implementation Method 3
Fibrous filter media are used in various types of filter devices to trap large and small particles in liquid and gas streams.
Data Source
AI summary
A nanofiber filter wrap is a filter element comprising a polymer film including a first surface, a second surface opposite the first surface, an array of nanofibers extending from the first surface, a first end, a second end opposite the first end, and opposing first and second edges extending from the first end to the second end. The polymer film is wound or folded to form a plurality of spaced adjacent layers defining interlayer gaps extending through the filter element from the first edge to the second edge substantially normal to a basal plane defined by the second edge of the polymer film. A fluid flowed can be flowed through the interlayer gaps to contact at least a portion of the array of nanofibers whereby a contaminant contained in the fluid is at least partially filtered from the fluid.