Sub-micron Polymer Binder for Porous Filtration Articles
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Solution Overview
Problem
Existing porous separation articles face challenges in achieving high loadings of functionalization while maintaining mechanical strength during pressurized fluid flow, as smaller functional particles clog binder surfaces, reducing binding efficiency and increasing the risk of article collapse.
Innovation Solution
The use of discrete polymer binder particles in the 50 to 500 nm range allows for high loadings (>0.5 wt %) of nano-particles, ensuring effective binding of primary active particles while maintaining mechanical strength, with the binder adhering at specific discrete points to form an organized, porous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If smaller functional particles are used to increase surface area and functional loading, then functionalization efficiency is improved, but binder surface becomes clogged and binding efficiency decreases
Solution Approach 1:
The patent changes the particle size parameter of the binder from conventional sizes (1-10 microns) to sub-micron sizes (50-500 nm). This parameter change allows the binder to maintain adequate surface area even when high loadings of functional particles are present, preventing surface clogging while providing sufficient binding sites. The sub-micron binder particles can effectively bind primary particles without being overwhelmed by the surface area demands of numerous small functional particles.
Solution Approach 2:
The patent creates a composite binder system using sub-micron polymer particles (50-500 nm) that combines the binding function with enhanced surface area characteristics. This composite approach allows the binder to simultaneously provide mechanical strength and sufficient surface area for binding, even in the presence of high concentrations of functional particles. The composite nature of the sub-micron binder enables it to function effectively as both a structural element and a binding agent.
2Quantity of substance
If higher loading of functional particles is used to enhance filtration functionality, then separation efficiency is improved, but mechanical strength of the article decreases
Solution Approach 1:
The patent changes the binder particle size parameter to sub-micron dimensions (50-500 nm), which fundamentally alters the binder's ability to distribute and support functional particles. The sub-micron binder creates a more uniform and finely distributed binding network throughout the article structure, providing mechanical strength even at high functional particle loadings. This parameter change enables the binder to act as an effective matrix that maintains structural integrity while accommodating high concentrations of functional particles.
3Strength
If more binder is used to maintain mechanical strength, then structural integrity is improved, but surface area of primary particles available for filtration decreases
Solution Approach 1:
The patent changes the binder particle size to sub-micron dimensions, which dramatically increases the surface area to volume ratio of the binder itself. This allows the binder to provide adequate mechanical strength with much lower overall binder content. The sub-micron binder particles can be distributed more uniformly and provide sufficient binding function without requiring high binder loadings that would otherwise cover and block the surface area of primary particles.
Solution Approach 2:
The patent uses a controlled amount of sub-micron binder that is sufficient to provide mechanical strength and binding function without excessive binder content. The sub-micron binder's high surface area efficiency means that only a small quantity is needed to achieve the desired binding and structural effects, leaving maximum surface area of primary particles available for filtration functionality.
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
This approach enables high loading of functionalization while maintaining sufficient mechanical strength, allowing for efficient filtration and interaction with fluid components, enhancing the separation efficiency of the porous article.
Implementation Method 1
the thermoplastic binder to connect the active particles or fibrous materials in discrete spots, rather than as a coating, forming an interconnected web
Implementation Method 2
The resulting composite solid article is porous, thereby permitting the fluid or gas to penetrate into and pass through the article
Implementation Method 3
the active powdery or fibrous materials to be in direct contact with, and to interact with, a fluid or gas
Implementation Method 4
used to separate, precipitate, and/or trap components of a fluid that passes through the porous article
Data Source
AI summary
The invention relates to a solid porous article containing sub-micron functional additive particles held together using discrete sub-micron polymer binder particles. The porous article preferably also contains a majority of primary active particles in the 1 to 300 micron range. The solid porous articles are used to separate, precipitate, and/or trap components of a fluid that passes through the porous article. The solid porous articles are used to separate and trap components of a fluid that passes through the porous article. Preferred binders are polyvinylidene fluoride resins, such as Kyblock® resins from Arkema Inc.