3D Projection Microfiltration Membrane for Throughput
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing microfiltration membranes face challenges in enhancing total throughput and flow rate without increasing the filter area, often resulting in reduced filtration efficiency due to clogging and increased hydrodynamic resistance.
Innovation Solution
A micro-porous filtration membrane with a multi-layer structure, featuring a pre-filter layer with larger pore size and an end-filter layer with smaller pore size, where at least one membrane layer includes three-dimensional projections formed by stamping, which act as spacers or macroscopic cavities to enhance the filtration surface area without compressing the micro-porous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filter area is enlarged to increase total throughput, then the dirt holding capacity increases, but the filter device size and costs increase
Solution Approach 1:
The patent applies dimensionality change by transforming the flat two-dimensional filter surface into a three-dimensional structure with protrusions and recesses. This creates additional filtration surface area within the same device footprint, effectively increasing total throughput without enlarging the filter device size. The protrusions extend into the third dimension (depth), providing more filtration area while maintaining the same external dimensions.
Solution Approach 2:
The patent implements nesting by creating recesses that penetrate into the filter layer, forming cavity structures within the filter material itself. These nested cavities provide additional surface area for filtration while being contained within the overall filter structure, allowing increased throughput without increasing external device size.
2Productivity
If more filter material is arranged compacted in the same device size to increase throughput, then the filter area remains constant, but the hydrodynamic resistance increases
Solution Approach 1:
By creating three-dimensional protrusions and recesses, the patent increases the effective filtration surface area without increasing the compacted density of filter material in the horizontal plane. This dimensional expansion allows more filtration surface while maintaining better fluid flow characteristics and reducing hydrodynamic resistance compared to simply compacting more material in the same area.
3Reliability
If the pore size is reduced to improve filtration efficiency, then the retention of small contaminants increases, but the flow rate decreases
Solution Approach 1:
The patent resolves this contradiction by increasing the surface area in the third dimension through protrusions and recesses. This allows the use of smaller pore sizes for high filtration efficiency while compensating for the reduced flow rate through increased total surface area, thereby maintaining or improving overall throughput.
Solution Approach 2:
The patent applies local quality by creating regions with different pore sizes in different layers - a pre-filter layer with larger pores for high throughput and a main filter layer with smaller pores for sterilizing effect. The three-dimensional structure ensures that both layers contribute effectively to filtration without either layer being blocked, maintaining both efficiency and flow rate.
4Productivity
If a pre-filter layer with larger pores is used to increase total throughput, then the dirt holding capacity increases, but the sterilizing effect may be compromised
Solution Approach 1:
The patent implements local quality by creating a multi-layer structure where the pre-filter layer has larger pores optimized for high throughput and dirt holding, while the main filter layer has smaller pores optimized for sterilizing effect. The three-dimensional protrusions and recesses ensure that both layers work synergistically, with the pre-filter capturing larger particles and the main filter providing sterilization, achieving both high throughput and reliable sterilization.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6(a)
AI summary
The present invention relates to a micro-porous filtration membrane with performance enhancing projections as well as a method for producing the same.