Polyester Filter Material for Leukocyte Removal
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Solution Overview
Problem
Nonwoven fabrics used for leukocyte removal filters undergo changes in thermal properties due to steam sterilization, affecting their leukocyte removal performance.
Innovation Solution
A filter material composed of polyester fibers with specific thermal properties, including a first and second endothermic peak in a DSC curve from 155° C. to 225° C., and a hydrophilic coating, which maintains high leukocyte removal performance even after steam sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam sterilization is applied to the nonwoven fabric filter material, then the filter material is sterilized to kill pathogens, but the thermal properties of the nonwoven fabric change, reducing leukocyte removal performance
Solution Approach 1:
The patent applies preliminary heat treatment at 155-225°C before steam sterilization to pre-stabilize the thermal properties of the nonwoven fabric. This preliminary action creates a thermal history that protects the fabric's pore structure during subsequent sterilization, preventing the degradation of leukocyte removal performance while still achieving effective sterilization.
Solution Approach 2:
The patent controls specific thermal parameters of the nonwoven fabric, particularly the crystallization temperature and degree of crystallinity, to optimize performance. By adjusting these parameters during heat treatment, the fabric maintains stable pore structure through sterilization, resolving the contradiction between sterilization effectiveness and filtration performance.
2Manufacturing precision
If the nonwoven fabric is made of ultrafine fibers with diameter of 10 μm or less to form small pores for leukocyte removal, then leukocyte removal performance is improved, but the fabric becomes more sensitive to thermal effects during steam sterilization
Solution Approach 1:
The patent optimizes the fiber diameter parameter to 10 μm or less for effective leukocyte removal, and simultaneously controls the thermal parameters (crystallization temperature 155-225°C and degree of crystallinity 30-70%) to reduce thermal sensitivity. This dual parameter control allows ultrafine fibers to maintain stable pore structure during sterilization while achieving high filtration performance.
Solution Approach 2:
The patent uses composite nonwoven fabric structures combining ultrafine polyester fibers with specific thermal properties. The composite structure includes fibers with controlled crystallinity and thermal stability, which together provide both the small pore sizes needed for leukocyte removal and the thermal resistance needed to withstand sterilization.
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 material achieves superior and consistent leukocyte removal performance, reducing changes in thermal properties and ensuring high filtration efficiency post-sterilization.
Implementation Method 1
the nonwoven fabric having a first endothermic peak at a melting point and a second endothermic peak having a maximum in a temperature range from 155° C. to 225° C. in a DSC curve obtained by differential scanning calorimetry (DSC)
Implementation Method 2
thermal effect of the steam sterilization produces a change in thermal properties of the nonwoven fabric of the filter material
Data Source
AI summary
A filter material for removing leukocytes including a nonwoven fabric composed of polyester fibers, the nonwoven fabric having a first endothermic peak at a melting point and a second endothermic peak having a maximum in a temperature range from 155° C. to 225° C. in a DSC curve obtained by differential scanning calorimetry (DSC).