Treated Filter Media for Water Coalescence in Hydrocarbon Filtration
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Solution Overview
Problem
Filtration systems for hydrocarbon fluids in internal combustion engines struggle to effectively remove free water, which can cause damage to engine components through cavitation and corrosion, and promote microbiological growth.
Innovation Solution
A filter element with a substrate layer having a treated surface that increases the roll-off angle and contact angle for water droplets, featuring pleats, flutes, and specific polymer compositions to enhance water coalescence and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional substrate layer is used, then the filter element structure is simple, but water droplets cannot be effectively coalesced and removed
Solution Approach 1:
The substrate layer is treated with a hydrophobic coating that provides different surface properties at the water-oil interface compared to the bulk material. This local modification creates a contact angle of 90-180 degrees, enabling water droplet coalescence without changing the entire substrate structure.
Solution Approach 2:
The surface energy parameters of the substrate layer are modified through hydrophobic treatment. This changes the contact angle and roll-off angle parameters, allowing water droplets to coalesce and roll off effectively while maintaining the substrate's structural integrity.
2Reliability
If the substrate layer is made hydrophilic, then water absorption increases, but water droplets cannot roll off effectively
Solution Approach 1:
The surface parameters are changed to achieve a balance: contact angle of 90-180 degrees for coalescence and roll-off angle of 50-90 degrees for droplet movement. This dual parameter optimization allows water to coalesce while maintaining roll-off capability.
Solution Approach 2:
The substrate combines a base material (polyester, polyolefin, or glass fiber) with a hydrophobic coating layer. This composite structure provides both the mechanical strength of the base material and the water-repelling properties of the coating, achieving effective water removal.
3Ease of manufacture
If a smooth substrate surface is used, then manufacturing is easier, but water droplets cannot coalesce effectively
Solution Approach 1:
Only the surface layer is modified with hydrophobic treatment while the bulk substrate remains simple and easy to manufacture. This local quality change enables effective water coalescence without complicating the manufacturing process.
Solution Approach 2:
The surface energy parameters are changed through coating or treatment to achieve the desired contact angle of 90-180 degrees. This parameter modification enables water coalescence while maintaining the simplicity of the substrate structure.
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 treated substrate layer effectively coalesces and removes water droplets, preventing engine damage and improving filtration efficiency.
Implementation Method 1
the treatment increases a roll off angle of the first surface for a 50 μL water droplet when the first surface is immersed in toluene
Implementation Method 2
the first surface has a contact angle in a range of 90 degrees to 180 degrees for a 50 μL water droplet when the first surface is immersed in toluene
Implementation Method 3
the substrate layer defines a plurality of pleats extending between a first set of pleat folds and a second set of pleat folds
Data Source
AI summary
The current technology relates to various filter elements configurations where a substrate layer defines a surface having a treatment. The treatment increases a roll off angle of the surface for a 50 water droplet when the surface is immersed in toluene. The filter element can have a housing and the substrate disposed in the housing. In some embodiments the substrate layer defines a plurality of pleats extending between pleat folds that form flow faces of the media. In some embodiments the substrate is incorporated into single facer media of a filter element. In some embodiments the substrate layer is incorporated in a filter element having a flow-by configuration. In some embodiments the substrate layer is incorporated in a filter element having a cross-flow configuration. Some embodiments relate to a vent. Some embodiments relate to a barrier assembly and/or a fuel filter element. Various other filter elements are described.