Single-Piece Porous Columns for Compact Tangential-Flow Filtration
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Solution Overview
Problem
Existing membrane filter modules face limitations in compactness and efficiency due to the use of multiple gaskets and separate plates, leading to restricted filter surface area and flow rate, with challenges in manufacturing and assembly of small-diameter ceramic columns.
Innovation Solution
A single-piece separator element comprising interconnected porous columns secured by inlet and outlet plates, eliminating the need for separate gaskets and plates, and fabricated using additive techniques to enhance compactness and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate gaskets and plates are used to assemble filter modules, then sealing and structural integrity are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (gaskets and plates) into a single integrated piece that performs both sealing and structural functions. This single-piece separator element integrates the sealing function previously performed by multiple gaskets and the structural support function previously performed by plates, thereby reducing device complexity while maintaining sealing integrity.
2Ease of manufacture
If conventional separate component assembly is used, then manufacturing and assembly are straightforward, but compactness and filter surface area are limited
Solution Approach 1:
The patent transitions from a two-dimensional arrangement of separate components to a three-dimensional integrated structure. The single-piece separator element utilizes vertical stacking and internal channel configurations that maximize filter surface area within the available volume, achieving higher compactness while maintaining manufacturing feasibility through additive techniques.
3Device complexity
If additive manufacturing techniques are used to create single-piece structures, then compactness and integration are improved, but manufacturing precision challenges arise
Solution Approach 1:
The patent employs additive manufacturing parameters and post-processing techniques to achieve the required dimensional accuracy and surface quality. By optimizing printing parameters, layer thickness, and material properties, the single-piece structure achieves the necessary precision for sealing surfaces and flow channels while maintaining the benefits of integrated design.
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 solution significantly increases the compactness of filter modules by at least 1.2 times, improves flow rate, and reduces manufacturing costs by eliminating the need for multiple gaskets and separate plates.
Implementation Method 1
a porous substrate that provides the membrane with mechanical strength and that also gives it a shape
Implementation Method 2
it enables certain components of the medium for treatment to pass through or to be stopped. Whether components pass through or are stopped is the result of their size compared with the size of the pores in the membrane, which then behaves as a filter
Implementation Method 3
the filtered fluid is transferred through the separator layer and the fluid then spreads out in the porous texture of the substrate in order to go towards the outside wall
Implementation Method 4
fabricated using additive techniques to enhance compactness and simplify assembly
Data Source
AI summary
A method of manufacturing a separator element for obtaining molecular and/or particulate separation by tangential flow of a fluid medium for treatment into a filtrate and a retentate, the element having a structure (2) of at least two porous rigid columns (3) made of the same material, positioned side by side to define, outside their outside walls, a volume (4) for recovering the filtrate, each column (3) presenting, internally, at least one open structure (5) for passing a flow of the fluid medium, opening out in one of the ends of the porous column for inlet of the fluid medium for treatment, and in the other end for outlet of the retentate. The element is a single-piece rigid structure (2) made as a single piece that is uniform and continuous throughout, without any bonds or exogenous additions.