Polyolefin Microporous Membrane for Compact Filtration
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Solution Overview
Problem
Nonwoven fabrics struggle to efficiently collect small particles (0.3 µm to 3.0 µm) and allow permeation of non-target substances, leading to increased filter size and reduced efficiency.
Innovation Solution
A polyolefin microporous membrane with specific properties: Gurley value of 0.01 to 20 seconds/100 mL, thickness of 25 to 150 µm, porosity of 80% to 98%, and average pore size of 0.30 to 0.60 µm, optionally with surface treatments, to enhance collection and permeation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nonwoven fabric thickness is increased to improve collection performance of small substances, then collection efficiency improves, but filter size increases
Solution Approach 1:
The invention uses a microporous membrane with controlled pore sizes (0.03-10 μm) and high porosity (30-90%) to achieve efficient particle collection. The porous structure allows small particles to be captured through physical filtration and adsorption mechanisms without requiring excessive material thickness, thus maintaining compact filter size while improving collection efficiency.
Solution Approach 2:
The invention optimizes multiple parameters including pore size distribution (0.03-10 μm), porosity (30-90%), and membrane thickness (1-100 μm) to achieve the desired balance between collection efficiency and filter size. By precisely controlling these parameters, the membrane can capture particles of 0.3-3.0 μm effectively while maintaining a thin profile.
2Reliability
If nonwoven fabric thickness is increased to improve collection performance of small substances, then collection efficiency improves, but processing efficiency decreases
Solution Approach 1:
The microporous membrane structure with optimized pore size (0.03-10 μm) and porosity (30-90%) enables efficient particle separation while maintaining high fluid permeability. This allows the membrane to capture small particles effectively without creating excessive flow resistance, thus preserving processing efficiency.
Solution Approach 2:
By optimizing the balance between porosity (30-90%) and pore size (0.03-10 μm), the membrane achieves both high collection efficiency for particles of 0.3-3.0 μm and adequate permeation performance for non-target substances, resolving the contradiction between reliability and productivity.
3Productivity
If filter is made thinner to improve processing efficiency, then permeation performance improves, but collection performance of small substances decreases
Solution Approach 1:
The microporous membrane utilizes a controlled pore size distribution (0.03-10 μm) and optimized porosity (30-90%) to achieve effective particle collection even at thin thicknesses (1-100 μm). The porous structure provides sufficient surface area and filtration pathways to capture particles of 0.3-3.0 μm while maintaining high permeation performance.
Solution Approach 2:
The membrane may incorporate composite structures or materials that enhance both filtration and permeation properties, allowing thin membranes to achieve high collection efficiency without sacrificing permeation performance.
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 membrane achieves balanced collection and permeation performance, maintaining filter life and efficiency while being thinner than nonwoven fabrics, with optional surface treatments for enhanced functionality.
Implementation Method 1
a substance is entangled and collected in the constituent fibers
Implementation Method 2
the amount of filter permeation per unit time for a substance that is not intended to be collected is preferably larger
Data Source
AI summary
A polyolefin microporous membrane containing a polyolefin, having a Gurley value of 0.01 seconds/100 mL or more and 20 seconds/100 mL or less, a thickness of 25 µm or more and 150 µm or less, a porosity of 80% or more and 98% or less, and an average pore size of 0.30 um or more and less than 0.60 µm.