Twisted Carbon-Infused Filter Fabric for Hydraulic Systems
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Solution Overview
Problem
Existing hydraulic filter materials face challenges in withstanding pressure differences and dynamic flow forces, often requiring metallic support structures to prevent electrostatic issues and ensure safety, particularly when filtering combustible fluids, which can lead to premature aging and safety risks.
Innovation Solution
A filter material with a support structure formed by a fabric of twisted threads, where at least one carrier thread is twisted with a conductive carbon thread, providing electrostatic protection without the need for metallic components, and utilizing plastic materials like polybutylene terephthalate, polypropylene, or polyethylene for strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic support structures (stainless steel wires) are used to withstand pressure differences and dynamic flow forces, then the mechanical strength and stability are improved, but electrostatic discharges and sparking risks occur when filtering combustible fluids
Solution Approach 1:
The patent applies composite materials by combining plastic carrier threads with conductive carbon threads to create a hybrid fabric structure. The plastic component provides mechanical strength and chemical resistance, while the carbon component provides electrostatic conductivity. This composite approach resolves the contradiction by eliminating the need for metallic materials that cause electrostatic discharge, while maintaining both mechanical integrity and electrostatic protection through the synergistic combination of different material properties.
Solution Approach 2:
The patent changes the material parameter from metallic to non-metallic (plastic-carbon composite) while maintaining the necessary functional properties. By modifying the material composition and structure of the support fabric - specifically incorporating conductive carbon threads into plastic carrier threads - the patent achieves electrostatic conductivity without using metals, thereby preventing electrostatic discharge while maintaining mechanical strength.
2Object-affected harmful factors
If non-metallic fiber fabrics are used to avoid electrostatic issues, then electrostatic discharge is reduced, but the ability to withstand pressure differences and dynamic flow forces deteriorates
Solution Approach 1:
The patent uses composite materials to overcome the weakness of pure non-metallic fabrics. By combining plastic carrier threads with conductive carbon threads, the fabric achieves both electrostatic conductivity and enhanced mechanical strength. The carbon threads reinforce the plastic structure, allowing the non-metallic fabric to withstand pressure differences and dynamic flow forces that would otherwise require metallic materials.
Solution Approach 2:
The patent applies local quality by strategically incorporating conductive carbon threads into specific positions within the fabric structure. Rather than using uniform metallic material throughout, the carbon threads are localized within the plastic carrier thread structure, providing electrostatic conductivity and mechanical reinforcement exactly where needed to withstand hydraulic pressures while maintaining overall non-metallic composition.
3Reliability
If metallic fabrics are used to ensure safety against electrostatic discharge, then electrostatic protection is improved, but the filtered fluid ages prematurely and safety risks remain
Solution Approach 1:
The patent replaces durable but harmful metallic materials with a non-metallic alternative that, while providing sufficient electrostatic protection, does not cause the same degradation effects on filtered fluids. The plastic-carbon composite fabric provides the necessary electrostatic conductivity to prevent charge buildup and discharge, thereby protecting the filtered fluid from electrostatic-induced aging and maintaining fluid lifespan.
Solution Approach 2:
The patent converts the potential harm of electrostatic discharge into a benefit by using conductive carbon threads that actively dissipate static charges before they can build up to dangerous levels. This prevents the harmful electrostatic discharge that would otherwise occur with non-conductive plastic fabrics, while avoiding the fluid degradation associated with metallic materials. The carbon threads transform the electrostatic problem into a controlled charge dissipation mechanism.
4Ease of manufacture
If plastic fabrics are used for rational manufacturability and cost-effectiveness, then ease of manufacture is improved, but electrostatic charging occurs during operation
Solution Approach 1:
The patent maintains the manufacturability and cost-effectiveness of plastic fabrics while eliminating electrostatic charging by incorporating conductive carbon threads into the plastic carrier thread structure. This composite approach allows the fabric to be manufactured using standard textile processes for plastic fabrics, preserving ease of manufacture and cost advantages, while the added carbon component provides the necessary electrostatic conductivity to prevent charge buildup during operation.
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 effectively prevents electrostatic discharges, ensures safety, and extends the lifespan of filtered fluids by using a carbon-infused fabric that is both strong and resistant to various chemicals, allowing for efficient and automated processing of filter elements.
Implementation Method 1
at least one conductive carbon thread is twisted with a relevant carrier thread... These problems can be avoided without having to form a metallic fabric, for example from stainless steel wires, by forming a fabric as the respective supporting structure in which twisted threads are contained, in which at least one conductive carbon thread is twisted with a relevant carrier thread
Data Source
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AI summary
The invention relates to a filter material, which is provided in particular for hydraulic filters, comprising at least one layer that comprises at least one first structure (18, 24), which has warp (32) and weft threads (36, 37), and at least one additional second structure (22) with specifiable filtration properties. The invention is characterized in that each first structure (18, 24) is at least partly made of multifilaments in the form of twisted threads (36).