Particulate Filter With Layered Ceramic Structure
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Solution Overview
Problem
Conventional filtration devices face limitations in efficiently removing nanometer-sized bacteria, viruses, and metal ions from water due to their pore size and structure, leading to compromised particulate size and pressure drop across the filter.
Innovation Solution
A particulate filter with a layered ceramic porous structure featuring a coarse-grain substrate, intermediate-grain layer, and fine-grain membrane, forming funnel-shaped channels that allow high flow rates and effective removal of solid particles and agents from liquid, while restricting reticulate particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filtration devices use smaller pore sizes to remove nanometer-sized particles, then particle removal efficiency is improved, but pressure drop across the filter increases
Solution Approach 1:
The filter is divided into multiple layers with different pore sizes: a coarse-grain support layer provides structural integrity and high flow capacity, while fine-grain filtration layers provide particle removal. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The filter combines ceramic materials with different grain sizes in a composite structure. The coarse-grain ceramic support provides mechanical strength and low resistance to flow, while the fine-grain ceramic filtration layer provides high particle removal efficiency. This composite approach resolves the contradiction between pressure drop and filtration efficiency.
2Manufacturing precision
If ceramic membranes with smaller pores are used to improve separation, then particle removal is improved, but flow rate decreases
Solution Approach 1:
The filter structure segments the flow path into two functional zones: the coarse-grain support layer handles the bulk flow with minimal resistance, while the fine-grain layer performs the separation function. This segmentation maintains high overall flow rates while achieving efficient particle removal.
Solution Approach 2:
Different regions of the filter have different pore sizes optimized for their specific functions. The support layer has large pores for high flow capacity, while the filtration layer has small pores for high separation efficiency. This local quality differentiation resolves the contradiction between flow rate and separation efficiency.
3Stability of the object's composition
If conventional ceramic membranes are used, then thermal and chemical stability is improved, but pore structure becomes tortuous leading to fouling
Solution Approach 1:
The filter segments the ceramic structure into coarse-grain support and fine-grain filtration layers. This segmentation creates a more open, less tortuous flow path compared to conventional dense ceramic membranes, reducing the tendency for fouling while maintaining the thermal and chemical stability of the ceramic material.
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 achieves high flow rates and high percentage removal of solid particles and agents, with up to 99.96% reduction of cesium and strontium ions, and flow rates comparable to or exceeding those of uncoated large-pore substrates, while maintaining thermo-mechanical strength and chemical stability.
Implementation Method 1
disposing a sol-gel membrane onto the substrate to form a filtration unit
Implementation Method 2
drying the filtration unit
Implementation Method 3
calcinating the filtration unit
Data Source
AI summary
A method is provided for producing a particulate filter to pass through select permeate particles in a fluid medium from inflow to outflow regions while restraining reticulate particles. The method includes providing an aluminum oxide substrate; disposing a sol-gel membrane onto the substrate to form a tiered filtration unit; drying the filtration unit; and calcinating the filtration unit.