Renewable Epoxy Impregnation for Filter Medium Strength
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Solution Overview
Problem
Existing filter media are produced from fossil fuels, leading to environmental concerns and reduced effectiveness over time, and existing renewable alternatives do not provide suitable properties for all filtration systems.
Innovation Solution
A filter medium impregnated with a cured epoxy resin formed by the reaction of an epoxy resin with a curing agent, where the epoxy resin includes a diglycidyl ether derived from renewable sources, maintaining filtration properties such as dry and wet bursting strength, stiffness, and chemical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fossil fuel-based polymeric resins are used to impregnate the base filter medium, then the filter medium achieves suitable properties for filtration systems, but the environmental impact increases due to consumable nature and fossil fuel usage
Solution Approach 1:
The patent changes the chemical composition parameters of the resin from fossil fuel-based polymers to lignin-based natural polymer, maintaining the impregnation function while reducing environmental impact. The lignin resin is applied at 0.1 to 30 wt.% of the fibrous web, providing suitable filter medium properties without fossil fuel dependency.
Solution Approach 2:
The patent creates a composite structure by impregnating the fibrous web with lignin resin, combining the base filter medium with a renewable polymer. This composite approach maintains filtration performance while replacing harmful fossil fuel-based materials with environmentally friendly lignin.
2Object-affected harmful factors
If lignin resin composition is used to reduce environmental impact, then renewable sourcing is achieved, but the filter medium does not provide suitable properties for all filtration systems
Solution Approach 1:
The patent optimizes the lignin resin parameters by specifying density less than 1.2 g/cm³ or weight average molecular weight less than 20000 g/mol. These parameter adjustments ensure the lignin resin provides suitable filtration properties including dust holding capacity, filter efficiency, and mechanical strength while maintaining renewable sourcing benefits.
Solution Approach 2:
The patent applies lignin resin with specific local properties (controlled density and molecular weight) to the fibrous web, ensuring the resin provides appropriate filtration characteristics for different filtration system requirements while maintaining environmental benefits.
3Reliability
If depth filtration is used to remove particles, then filter efficiency is improved, but the pores become blocked over time reducing fluid flow and requiring replacement
Solution Approach 1:
The patent modifies the pore structure parameters of the filter medium by impregnating with lignin resin, creating tortuous pathways that trap particles while maintaining adequate porosity for fluid flow. The resin concentration of 0.1 to 30 wt.% optimizes the balance between particle retention and flow characteristics.
Solution Approach 2:
The patent creates a composite filter medium where lignin resin forms a matrix within the fibrous web, providing both particle trapping capability and maintained fluid permeability. This composite structure delays pore blocking and extends service life while preserving depth filtration efficiency.
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 use of renewable epoxy resin improves the filter medium's properties without detrimentally affecting its filtration performance, reducing environmental impact while extending its lifespan.
Implementation Method 1
The cured epoxy resin is formed by the reaction of an epoxy resin with a curing agent
Implementation Method 2
The epoxy resin comprises a diglycidyl ether formed by the reaction of a diol with an epihalohydrin
Data Source
AI summary
Described herein is a filter medium comprising a base filter medium impregnated with a cured epoxy resin formed by the reaction of an epoxy resin with a curing agent, wherein the epoxy resin comprises a diglycidyl ether formed by the reaction of a diol with an epihalohydrin; wherein at least the epihalohydrin is derived from renewable sources. Also described herein is a filtration device formed therefrom and a method of producing a filter medium.