Phosphoric Acid Impregnated Filter Medium for Metal-Working Liquid Recycling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Metal-working liquids used in aluminum product manufacturing become contaminated with metal fines and soaps, leading to quality issues and equipment damage, as existing methods require frequent replacement or batch-wise treatment, causing fluctuating contaminant levels that affect process quality.
Innovation Solution
A filter medium comprising a carrier such as cellulosic material, clay, or diatomaceous earth impregnated with phosphoric acid or its derivatives, which sequesters metal fines and soaps, producing a filtrate substantially free of ashable residues, allowing for continuous recycling of the metal-working liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch-wise replacement or treatment of metal-working liquid is used, then the liquid can be replaced or treated periodically, but contaminant levels fluctuate from low to high which affects quality consistency
Solution Approach 1:
The patent implements continuous filtration and treatment of metal-working liquid through a filter medium that constantly removes contaminants as the liquid circulates, eliminating the batch-wise replacement approach. This ensures contaminant levels remain consistently low throughout operation, maintaining quality consistency while enabling continuous production without interruption.
2Productivity
If metal-working liquid is continuously circulated and filtered, then heat removal and contaminant filtration are maintained, but the liquid eventually becomes increasingly contaminated requiring replacement
Solution Approach 1:
The patent employs a filter medium with chemical agents that actively capture and retain metal fines and soap contaminants on the filter cartridges, while allowing the cleaned metal-working liquid to be continuously reused. This recovery process extends the service life of the liquid significantly, reducing replacement frequency from periodic batch replacement to extended continuous operation.
3Reliability
If filter medium with chemical agent is used to sequester metal fines, then filtration effectiveness increases, but the filter medium requires periodic replacement
Solution Approach 1:
The patent utilizes chemical agents impregnated on the filter medium that undergo parameter changes through chemical reactions with contaminants. These agents chemically bind metal fines and soaps, transforming them into removable complexes. The filter medium is designed to maintain high filtration effectiveness throughout its service life, with replacement scheduled based on accumulated contaminant capacity rather than performance degradation.
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 removes at least 99.99% of metal fines and soaps, reducing ash residue to less than 0.0001 wt. %, ensuring consistent quality and extending the life of metal-working liquids by maintaining low contaminant levels.
Implementation Method 1
The chemical agent sequesters metal fines from metal-working liquids filtered through the filter medium
Data Source
AI summary
The technology presents filter media and methods of recycling metal-working liquids by removing metal fines and other contaminants using the filter media. An exemplary method includes a series of steps. These steps include filtering a contaminated metal-working liquid that has metal fines through an exemplary filter medium that is comprised of a carrier and a chemical agent. The carrier is impregnated with a chemical agent selected from the group consisting of phosphoric acid, polyphosphoric acid, phosphorous acid, phosphorous pentoxide, and mixtures or derivatives of these. Further, the exemplary method includes collecting a filtrate substantially free of ashable residue; and reusing the filtrate as a metal-working liquid.