Thin Filtration Media Retaining Fluted Structures
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Solution Overview
Problem
Existing filtration media struggle to maintain structured flutes without cracking or tearing, especially under vibrations, and often fail to retain shape during use due to inadequate retention of flute structures with sharp peaks and ridges.
Innovation Solution
A method for manufacturing a thin, lightweight filtration media using a wet-laid fibrous web with a controlled wet Mullen ratio, comprising a blend of cellulose and synthetic fibers with a phenolic resin binder, allowing for flexible and strong media that can retain fluted structures without additional curing, and ensuring high tear resistance and air permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing filtration media are formed into structured flutes with sharp peaks and ridges, then the media can provide z-flow filtration capability, but the media become difficult to form without cracking or tearing
Solution Approach 1:
The patent changes the physical parameters of the filtration media by controlling the resin cure state to achieve a specific wet Mullen ratio range (30-80%). This parameter adjustment makes the media flexible enough to be formed into structured flutes with sharp peaks and ridges without cracking or tearing, while still maintaining sufficient strength for handling and installation.
Solution Approach 2:
The patent uses a composite material system consisting of fibrous web combined with resin binder at specific ratios. This composite structure provides both the flexibility needed for forming complex flute shapes and the strength required to maintain structural integrity during manufacturing and use.
2Adaptability or versatility
If existing filtration media are formed into structured flutes, then they can provide enhanced filtration performance, but the peaks and ridges fail to retain their shape after forming and during use
Solution Approach 1:
The patent optimizes the resin content and cure state parameters to achieve a wet Mullen ratio of 30-80%. This specific parameter range allows the media to retain sharp flute peaks and ridges during use, preventing deformation while maintaining the desired structured configuration for z-flow filtration.
Solution Approach 2:
The patent applies resin binder and controls curing before the forming process to pre-strengthen the media structure. This preliminary action ensures that when the media is formed into structured flutes, the peaks and ridges maintain their shape throughout the forming process and during subsequent use.
3Weight of moving object
If the media are made thin and lightweight for compact design, then they improve fluid flow and reduce pressure drop, but they become more susceptible to tearing and degradation
Solution Approach 1:
The patent creates a composite structure by impregnating the fibrous web with resin binder. This composite approach allows the media to be made thin and lightweight for compact filter element design while the resin reinforcement prevents tearing and degradation, maintaining reliability despite reduced thickness.
Solution Approach 2:
The patent adjusts the resin-to-fiber ratio and cure state parameters to achieve optimal strength-to-weight ratio. By controlling these parameters, the media can be made thin (reducing weight and pressure drop) while still providing sufficient tear resistance and durability for practical applications.
4Strength
If additional curing is performed during pleating/fluting to improve shape retention, then the media become stronger, but they require more processing time and energy
Solution Approach 1:
The patent applies partial curing by controlling the resin cure state to achieve a wet Mullen ratio of 30-80% rather than complete curing. This partial action provides sufficient strength for shape retention during forming and use, while reducing processing time and energy consumption compared to full curing.
Solution Approach 2:
The patent optimizes curing parameters (temperature, time, resin type) to achieve the target wet Mullen ratio range. By precisely controlling these parameters, the media gains adequate strength for structural integrity without requiring excessive curing time and energy input.
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 provides filtration media that is flexible, strong, and capable of retaining fluted structures, with improved tear resistance and air permeability, suitable for various filtration applications, including z-flow elements, while maintaining the desired level of shape retention and fluid permeability.
Implementation Method 1
comprising a blend of cellulose and synthetic fibers with a phenolic resin binder
Implementation Method 2
The media are typically porous to permit fluid to flow through the media while at the same time trapping particulate contaminants in the media
Data Source
AI summary
A method for manufacturing a filtration media with improved filtration, strength, tear resistance and air permeability in the form of a relatively thin and lightweight wet-laid fibrous web that has a wet Mullen ratio of 20% to 90% to ensure that the media is flexible enough to be formed into a fluted structure, and strong enough to retain the fluted structure when would into a roll and to permit further processing.