Polymeric Nanoweb Fuel Filter for Diesel Engine Injector Protection
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Solution Overview
Problem
Existing fuel filters for diesel engines struggle to achieve 99% efficiency in removing particles of 4 microns and higher without using glass media, which poses a risk to injector systems due to potential glass fiber contamination.
Innovation Solution
A fuel filter design incorporating a polymeric nanoweb filter layer made of synthetic resins, with a basis weight between 2.5 gsm and 13 gsm, in combination with upstream and downstream scrims, that does not use glass media, providing a 99% efficiency in particle removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass media is used in the fuel filter, then filtration efficiency can be achieved, but glass fibers may separate and contaminate the injector system
Solution Approach 1:
The patent removes glass media entirely from the fuel filter construction and replaces it with an all-polymer nanoweb structure. This extraction of the harmful glass component eliminates the risk of glass fiber contamination while maintaining filtration functionality through the polymeric nanoweb's fine pore structure and high surface area-to-volume ratio.
Solution Approach 2:
The patent employs a composite structure consisting of multiple polymeric layers including a nanoweb layer, scrim layers, and potentially other filter media. This composite approach combines the high filtration efficiency of the nanoweb with the structural support and durability of the scrim and other polymer layers, achieving both high reliability and safety without glass.
2Object-affected harmful factors
If non-glass media such as meltblown and wetlaid cellulose is used, then glass fiber contamination is avoided, but filtration efficiency only reaches about 96%
Solution Approach 1:
The patent changes the fundamental parameters of the filter media by introducing a polymeric nanoweb structure with significantly different physical properties than conventional meltblown or wetlaid cellulose. The nanoweb's ultra-fine fiber diameter, high porosity, and large surface area create a filtration mechanism that achieves 99%+ efficiency at 4 microns, surpassing the performance of traditional non-glass media.
3Reliability
If a polymeric nanoweb filter layer with basis weight between 2.5 gsm and 13 gsm is used, then 99% filtration efficiency is achieved without glass, but the filter structure becomes more complex
Solution Approach 1:
The patent divides the filter into distinct functional layers: a polymeric nanoweb layer for high-efficiency particle filtration, scrim layers for structural support, and potentially coalescing media for liquid separation. Each layer is optimized for its specific function, allowing the nanoweb to focus on particle removal while the scrim provides mechanical integrity, thereby managing complexity through functional specialization.
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 achieves high efficiency in removing 4-micron particles and above, ensuring the safety of diesel engine injector systems by eliminating the risk of glass fiber contamination while maintaining effective filtration performance.
Implementation Method 1
a polymeric nanoweb filter layer consisting of synthetic resins, of basis weight between 2.5 gsm and 13 gsm
Data Source
AI summary
Disclosed herein is an engine fuel filter containing a filter medium of a filtering mass of a nanoweb preferably situated between two scrims. The scrims can be nonwoven webs and the filtering mass is located in an enclosure so as to be crossed by the fuel in its path inside the filter. The nanoweb has a basis weight between about 1.5 gsm and about 40 gsm, and can be in face-to-face and fluid contact with either or both of the upstream and downstream scrims. The nanoweb does not contain glass.