Water Filter Dimensional Accuracy via Grinding and Particle Sizing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing water-processing filters face challenges in achieving high dimensional accuracy and filterability while maintaining the capability to remove free residual chlorine, volatile organic compounds, and turbidity components, with low yield due to compression treatments that affect the structural integrity and packing density of granular activated carbon filters.
Innovation Solution
A cylindrical water-processing filter is produced using a slurry suction method with a granular activated carbon having a median particle size of 30 to 80 μm and a fibrillated fibrous binder, where the outer surface is ground instead of compressed, resulting in improved dimensional accuracy and filterability, and a secondary cylindrical filter with a granular binder is inserted into the hollow space to enhance strength and filtration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression treatment is applied to improve the shape and dimensional accuracy of the cartridge, then the dimensional accuracy is improved, but the capability to filter out turbidity components decreases
Solution Approach 1:
The invention changes the particle size parameter of activated carbon from conventional larger sizes to specifically 10 μm or smaller (with D90 of 20 μm or smaller), and adjusts the specific surface area to 1500 m²/g or larger. These parameter changes enable the carbon to maintain structural integrity after compression while providing sufficient surface area for effective filtration, thus resolving the contradiction between dimensional accuracy and filterability.
Solution Approach 2:
The invention uses a composite structure combining activated carbon particles (10 μm or smaller) with a binder material, creating a molded product that can withstand compression forces. The specific composition and bonding create a structurally sound cartridge that maintains its shape after compression treatment while preserving the fine particle characteristics necessary for high filterability.
2Shape
If compression treatment is applied to arrange the shape of the molded product, then the shape is improved, but the capability to remove turbidity components decreases
Solution Approach 1:
By changing the particle size parameter to 10 μm or smaller with D90 of 20 μm or smaller, the activated carbon maintains its filtration effectiveness even after compression. The fine particle size allows the carbon to conform to the molded shape while retaining sufficient surface area for turbidity removal, thus resolving the contradiction between shape arrangement and turbidity removal capability.
3Manufacturing precision
If excessive compression is applied to improve dimensional accuracy, then the dimensional accuracy is improved, but the surface consolidation occurs reducing filterability
Solution Approach 1:
The invention changes the particle size to 10 μm or smaller, which allows the activated carbon to maintain structural integrity and porosity even under compression. The fine particles can rearrange and conform to the mold cavity without consolidating the surface, thus achieving high dimensional accuracy while maintaining filterability.
Solution Approach 2:
The invention performs preliminary action by pre-treating the activated carbon particles to achieve the specific size distribution (10 μm or smaller, D90 of 20 μm or smaller) and high specific surface area (1500 m²/g or larger) before molding. This preliminary preparation ensures that the particles can withstand subsequent compression without surface consolidation, thus resolving the contradiction between dimensional accuracy and filterability.
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 approach results in a filter with enhanced dimensional accuracy, improved filterability, and high yield, capable of effectively removing free residual chlorine, volatile organic compounds, and turbidity components, while maintaining structural strength.
Implementation Method 1
a slurry suction method, as disclosed in Japanese Patent No. 3516811 or others. The slurry suction method comprises sucking a slurry from the inside of a cylindrical forming die having small suction holes to accumulate the slurry on the surface of the die
Implementation Method 2
the outer surface of the molded product is ground
Implementation Method 3
removal of harmful substances (e.g., free residual chlorine, trihalomethanes, and mold odors) contained in drinking water
Implementation Method 4
water purifiers having a housing filled with a granular activated carbon
Data Source
AI summary
A water-processing filter having a high dimensional accuracy and an improved filterability (such as a capability to remove turbidity components) is provided. The water-processing filter comprises (A) a hollow cylindrical filter which comprises (a1) a granular activated carbon having a median particle size of 30 to 80 μm and (a2) a fibrillated fibrous binder. The cylindrical filter (A) has an upstream outer surface having an arithmetical mean deviation of a waviness profile adjusted to not more than 30 μm and an arithmetical mean deviation of a primary profile adjusted to 35 to 45 μm. The cylindrical filter (A) may have a downstream inner surface having an arithmetical mean deviation of a waviness profile of not more than 30 μm and an arithmetical mean deviation of a primary profile of 35 to 45 μm. The cylindrical filter (A) may have a grounded outer surface. In a hollow space of the cylindrical filter (A), (B) a cylindrical filter comprising (b1) a granular activated carbon having a median particle size of 30 to 80 μm and (b2) a granular binder may be disposed.