Acrylate adhesive compositions for housings of spiral wound membrane filters

Abstract

The present invention features a spiral wound membrane filter comprising a housing comprising a reinforcing material and an acrylate adhesive composition comprising a polyfunctional (meth) acrylate wherein the adhesive composition has a viscosity of not more than 10,000 cP when measured according to ASTM D1084 Test Method B at 23 DEG C.

Description

Background Technology

[0001] This invention relates to the use of acrylic adhesives for forming the housing of spiral wound membrane filters.

[0002] Two-component epoxy-based adhesive compositions are commonly used as structural adhesives in filters. However, the curing time for two-component epoxy-based adhesives can be up to 12 hours. There is a need for a structural adhesive for the housing of spiral wound membrane filters that can cure rapidly for immediate operation. Summary of the Invention

[0003] Overview

[0004] In one aspect, the invention is characterized by a spiral wound membrane filter comprising a housing including a reinforcing material and an acrylate adhesive composition comprising 20% ​​to 90% by weight of a polyfunctional (meth)acrylate, wherein the acrylate adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0005] In one aspect, the invention is characterized by a spiral wound film comprising a shell, the shell comprising a reinforcing material and an acrylate adhesive composition comprising 15 wt% to 60 wt% of a multifunctional (meth)acrylate oligomer, 30 wt% to 80 wt% of a (meth)acrylate monomer and 0.2 wt% to 5 wt% of a photoinitiator, wherein the acrylate adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0006] In one embodiment, the acrylate adhesive composition has a viscosity of not more than 5,000 cP when measured at 23°C according to ASTM D1084 Test Method B. In another embodiment, the acrylate adhesive composition has a viscosity of not more than 2,500 cP when measured at 23°C according to ASTM D1084 Test Method B. In yet another embodiment, the acrylate adhesive composition has a Shore D hardness of D60 to D100 as tested according to the Shore D Hardness test method. In one embodiment, the polyfunctional (meth)acrylate is selected from polyfunctional (meth)acrylate oligomers, (meth)acrylate monomers, and combinations thereof. In a different embodiment, the polyfunctional (meth)acrylate oligomer is selected from urethane acrylate, epoxy acrylate, polyester acrylate, acrylic acrylate, polyether acrylate, polybutadiene acrylate, and combinations thereof. In another embodiment, the multifunctional (meth)acrylate oligomer comprises aliphatic urethane acrylates. In one embodiment, the (meth)acrylate monomer comprises isobornyl acrylate monomer. In a different embodiment, the (meth)acrylate monomer comprises at least two (meth)acrylate monomers.

[0007] In one different implementation, the at least two (meth)acrylate monomers include monofunctional monomers and polyfunctional monomers.

[0008] In one embodiment, the acrylate adhesive composition further comprises an initiator selected from photoinitiators, thermal initiators, and combinations thereof. In another embodiment, the acrylate adhesive composition comprises a photoinitiator, said initiator comprising at least two different photoinitiators.

[0009] In one embodiment, the reinforcing material is selected from continuous strands, webs, loosely woven fabrics, and nonwoven fabrics. In another embodiment, the reinforcing material is continuous glass fiber strands.

[0010] In one aspect, the invention is characterized by a method of manufacturing a housing for a spiral wound membrane filter, comprising the steps of: obtaining an acrylate adhesive composition comprising a polyfunctional (meth)acrylate and an initiator; passing at least one continuous strand of reinforcing material through the acrylate adhesive composition; wrapping the continuous strand around the periphery along the entire length of the spiral wound membrane filter; and exposing the continuous strand of reinforcing material coated with the acrylate adhesive composition to an energy source at a time selected from during, after, and combinations thereof.

[0011] In one embodiment, the continuous strands of the reinforcing material are glass fibers.

[0012] In another embodiment, the energy source is selected from ultraviolet light, visible light, electron beam radiation, microwave radiation, heat, and combinations thereof. In a different embodiment, the energy source is selected from ultraviolet light, visible light, heat, and combinations thereof.

[0013] The housing of a spiral wound membrane filter is typically formed by winding glass fibers coated with an uncured liquid resin (such as a two-component epoxy) around a spiral wound separator element. The filter is then cured at room temperature or exposed to higher temperatures to accelerate curing. The equipment required for mixing and pumping the two-component epoxy and the time required to cure the final filter increase the time and cost of the method and therefore the final filter.

[0014] The present invention is characterized by an acrylic adhesive composition having the desired properties for forming the housing of a spiral wound membrane filter.

[0015] Other features and advantages will become apparent from the following description of the preferred embodiments and the claims.

[0016] Glossary

[0017] Regarding this invention, the following terms have the meanings set forth below: As used herein, the term "(meth)acrylate" is an abbreviation for acrylate, methacrylate, or combinations thereof.

[0018] As used herein, the term "polyfunctional (meth)acrylate" refers to a (meth)acrylate that includes at least two (meth)acrylate groups.

[0019] As used in this article, “ultraviolet light” is defined as having a wavelength of 100 nanometers (nm) to 405 nm.

[0020] As used in this article, "visible light" is defined as having a wavelength of >405 nm to 760 nm. Detailed Implementation

[0021] Detailed Explanation

[0022] Spiral wound membrane filter

[0023] In membrane filtration, filter elements (e.g., semi-permeable membranes) are used to remove impurities from a liquid. Membrane filtration can be used in a wide variety of applications, including those selected from reverse osmosis, forward osmosis, nanofiltration, ultrafiltration, and microfiltration.

[0024] A spiral wound filter element is formed by spirally winding one or more membrane envelopes and optionally a feed channel spacer sheet around a center core collection tube. Each membrane envelope preferably contains two generally rectangular membrane sheets surrounding the permeate channel spacer sheet. This sandwich structure is held together along three sides by adhesive, while a fourth side firmly abuts against the permeate collection tube, such that the permeate spacer is in contact with fluid flowing through the opening in the permeate collection tube. The liquid to be filtered enters the membrane module from one end. Once inside the module, filtration occurs when pressure is applied to drive the cleaning liquid through the membrane surface. Exiting the module at the other end, the cleaning liquid travels through the center core collection tube (where it has been collected), and the concentrated waste liquid passes through the membrane. The spiral wound membrane filter may further include end caps at the ends of the filter to help secure the membrane in place.

[0025] Spiral wound membrane filters come in various sizes. For larger filters, in some cases with a diameter greater than 2-4 inches, the housing surrounds the outer perimeter of the filter to help maintain its shape and protect it.

[0026] The present invention is characterized by a spiral wound membrane filter comprising a housing, the housing comprising a reinforcing material and an acrylate adhesive composition comprising a polyfunctional (meth)acrylate, wherein the adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0027] The present invention is characterized by a spiral wound membrane filter comprising a housing comprising a reinforcing material and an acrylate adhesive composition comprising 20% ​​to 90% by weight of a polyfunctional (meth)acrylate, wherein the adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0028] In one aspect, the invention is characterized by a spiral wound membrane filter comprising a housing including a reinforcing material and an acrylate adhesive composition comprising 5% to 90% by weight of a polyfunctional (meth)acrylate, wherein the acrylate adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0029] The present invention is characterized by a spiral wound membrane filter comprising a housing, the housing comprising a reinforcing material and an acrylate adhesive composition comprising a polyfunctional (meth)acrylate and a photoinitiator, wherein the adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0030] The invention is further characterized by a spiral wound membrane filter comprising a housing comprising a reinforcing material and an acrylate adhesive composition comprising 15% to 60% by weight of a multifunctional (meth)acrylate oligomer, 30% to 80% by weight of a (meth)acrylate monomer, and 0.5% to 5% by weight of a photoinitiator, wherein the adhesive composition has a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B.

[0031] This invention provides a novel way of forming the housing of a spiral wound membrane filter that is simpler (single-component instead of two-component), faster, and provides the required strength and rigidity.

[0032] Outer shell

[0033] The housing surrounds the outer peripheral surface of the membrane filter and helps maintain the filter's shape and protect it. The housing comprises reinforcing material and an acrylic adhesive composition. The acrylic adhesive composition in the housing is cured by exposing the composition to an energy source. The energy source may be selected from ultraviolet light, visible light, electron beam radiation, microwave radiation, heat, or combinations thereof. Alternatively, the energy source may be selected from ultraviolet light, visible light, heat, or combinations thereof.

[0034] Acrylic adhesive compositions can be cured during the manufacture of the casing, after the casing is made, or in combination thereof. When the method for curing the acrylic adhesive composition includes exposing the composition to light, the acrylic adhesive composition may contain a photoinitiator. When the method for curing the acrylic adhesive composition includes heating the acrylic adhesive composition, the acrylic adhesive composition may contain a thermal initiator. Acrylic adhesive compositions may contain both a thermal initiator and a photoinitiator.

[0035] Reinforcing Material

[0036] The reinforcing material can be selected from continuous strands, webs, scrims, and nonwoven fabrics. Continuous strands are the most common type of reinforcing material. Reinforcing materials can also be selected from glass fibers, carbon fibers, aramids (e.g., Kevlar), or any other material that, when combined with adhesives, forms a tough-burst-proof shell to protect the filter.

[0037] Acrylic Adhesive Composition

[0038] This adhesive composition is a one-component, 100% solid acrylate adhesive composition. In one embodiment, the acrylate adhesive composition does not contain isocyanate functional groups. The acrylate adhesive composition contains polyfunctional (meth)acrylates. The acrylate adhesive composition may contain 15% to 90% by weight of polyfunctional (meth)acrylates. The acrylate adhesive composition may contain polyfunctional (meth)acrylates and a photoinitiator. The acrylate adhesive composition may contain 15% to 60% by weight of polyfunctional (meth)acrylate oligomers, 30% to 80% by weight of (meth)acrylate monomers, and 0.5% to 5% by weight of a photoinitiator.

[0039] The acrylic adhesive composition is sufficiently hard to provide a robust shell for the filter. The acrylic adhesive composition may have a Shore D hardness greater than 60, greater than 65, greater than 70, from 50, 55, 60, 65 to 85, 90, 95, 100, or any two values ​​between them.

[0040] When measured at 23°C according to ASTM D1084 Test Method B, the acrylic adhesive composition may have a viscosity of no more than 10,000 cP, no more than 7,500 cP, no more than 5,000 cP, no more than 2,500 cP, no more than 1,500 cP, 10 cP to 10,000 cP, 10 cP to 7,500 cP, 10 cP to 2,500 cP, 10 cP to 1,500 cP, 50 cP to 1,200 cP, or even 250 cP to 1,200 cP. Lower viscosity is particularly advantageous when the reinforcing material is a strand coated with the acrylic adhesive composition and wound around the outside of the film.

[0041] Multifunctional (meth)acrylates

[0042] The polyfunctional (meth)acrylate contains at least two olefinically unsaturated functional groups. Preferably, the at least two olefinically unsaturated functional groups are located at the end of the polyfunctional (meth)acrylate. The polyfunctional (meth)acrylate can be selected from oligomers, monomers, and combinations thereof.

[0043] The acrylic adhesive composition may have a polyfunctional (meth)acrylate content ranging from 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt% to 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt% or any two of these values.

[0044] Multifunctional (meth)acrylate oligomers

[0045] Acrylic adhesive compositions may contain polyfunctional (meth)acrylate oligomers. Acrylic adhesive compositions may contain more than one (meth)acrylate oligomer. The polyfunctional (meth)acrylate oligomer may be selected from urethane, ester, epoxy, and butadiene (meth)acrylate oligomers.

[0046] In one aspect of the invention, the (meth)acrylate oligomer is a polyether or polyester urethane acrylate oligomer. The (meth)acrylate-functionalized polyether or polyester urethane component can be synthesized by reacting a diisocyanate with a polyether or polyester polyol to produce an isocyanate-terminated urethane. The isocyanate-terminated urethane is then reacted with a hydroxyl-terminated acrylate to provide acrylate groups at the ends of the oligomer. The multifunctional (meth)acrylate oligomer can be fully reacted such that no free isocyanate groups are present. Alternatively, if the terminal isocyanate does not fully react with the hydroxyl acrylate, the isocyanate will remain in the structure as a reactive group other than the acrylate terminal group. This may be helpful if additional strength is required.

[0047] Multifunctional (meth)acrylate oligomers are available under various trade names, including, for example, GENOMER 4316, GENOMER 4215, GENOMER 4267, GENOMER 2235, GENOMER 2281, GENOMER 2263 and GENOMER 3486, all available from RAHN USA Corp (Aurora, Illinois), and EBERCRYL 8465 and EBERCRYL 8411, available from Allnex Netherlands BV.

[0048] Based on the weight of the components in the acrylate adhesive composition, the acrylate adhesive composition contains an amount of (meth)acrylate oligomer from 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt% to 40 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt% or any two of these values.

[0049] (meth)acrylate monomers

[0050] (Meth)acrylate monomers can be multifunctional (bifunctional, trifunctional, etc.) or monofunctional. (Meth)acrylate monomers can act as diluents and can be used to adjust the viscosity of acrylic adhesive compositions. Acrylic adhesive compositions can contain more than one (meth)acrylate monomer; for example, an adhesive composition can contain a blend of multifunctional and monofunctional monomers.

[0051] (Meth)acrylate monomers contain at least one olefinically unsaturated functional group, or even at least two olefinically unsaturated functional groups.

[0052] Suitable monofunctional (meth)acrylate monomers include, for example, methyl (meth)acrylate, isopropyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, steryl(meth)acrylate, 2-hexyl (meth)acrylate, octyl (meth)acrylate, isooctyl (meth)acrylate, decyl (meth)acrylate, isodecanyl (meth)acrylate, dodecyl (meth)acrylate, tetradecyl (meth)acrylate, phenoxyethyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, glycidyl (meth)acrylate, hydroxyethyl (meth)acrylate, hydroxypropyl (meth)acrylate, hydroxybutyl (meth)acrylate, benzyl (meth)acrylate, dicyclopentyl (meth)acrylate, and combinations thereof.

[0053] Suitable polyfunctional (meth)acrylate monomers include, for example, ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, 1,3-butanediol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, cyclohexanediol di(meth)acrylate, dicyclopentyl di(meth)acrylate, tri(meth)acrylate, trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, hexafunctional aliphatic acrylate monomers, tri(2-hydroxyethyl)isocyanurate tri(meth)acrylate, their alkoxylated forms, and combinations thereof.

[0054] (Meth)acrylate monomers can be aliphatic acrylates. Aliphatic acrylates can help improve the water resistance of acrylate adhesive compositions and therefore the casing. (Meth)acrylate monomers can be selected from isobornyl acrylate, polyether acrylate, tricyclodecanediethanol diacrylate, and hexafunctional aliphatic acrylates.

[0055] (Meth)acrylate monomers can exhibit viscosities of no more than 1,500 cP, no more than 1,000 cP, no more than 500 cP, no more than 150 cP, 5 cP to 1,500 cP, or even 5 cP to 1,000 cP at 25°C.

[0056] (Meth)acrylate monomers are available under various trade names, including, for example, GENOMER 1121Y, GENOMER 7302, MIRAMER M262 and MIRAMER M600, all of which are available from RAHN USA Corp (Aurora, Illinois).

[0057] Based on the weight of the components in the acrylate adhesive composition, the acrylate adhesive composition contains an amount of (meth)acrylate monomer from 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt% to 40 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, 75 wt% or any two of these values.

[0058] Initiator

[0059] Acrylic adhesive compositions optionally include an initiator. Available initiators include thermal initiators, photoinitiators, and mixtures thereof.

[0060] The available thermal initiators have a half-life of 10 hours at temperatures not exceeding 70°C, not exceeding 60°C, not exceeding 50°C, not exceeding 40°C, not exceeding 30°C, or even from approximately 30°C to approximately 70°C. Available thermal initiators include, for example, organic peroxides (such as di(4-tert-butylcyclohexyl) peroxydicarbonate, tert-butyl peroxyneodecanate, di(2-ethylhexyl) peroxydicarbonate), benzoyl peroxide, lauroyl peroxide, 2,2-azobisisobutyronitrile, t-butyl peroxypivalate, α,α'-bis(neodecanylperoxy)diisopropylbenzene, cumyl peroxyneodecanate, t-hexyl peroxypivalate, 1,1,3,3-tetramethylbutyl peroxyneodecanate, 1,1,3,3-tetramethylbutyl peroxy-2-ethylhexanoate, t-amyl peroxypivalate, isobutyryl peroxide, and succinic acid peroxide. peroxide), 3,5,5-trimethylhexanoyl peroxide, dimethoxybutyl peroxydicarbonate, di(sec-butyl) peroxydicarbonate, tert-butyl peroxyheptanate, di(3,5,5-trimethylhexanoyl) peroxide, di(sec-butyl) peroxydicarbonate and combinations thereof.

[0061] Suitable thermal initiators are available under various trade names, including, for example, PERKADOX 16 di(4-tert-butylcyclohexyl) peroxydicarbonate and TRIGONOX 23 tert-butyl peroxyneodecanate, both of which are available from Nouryon Chemical (Chicago, Illinois), PEROXAN EPC di(2-ethylhexyl) peroxydicarbonate from Pergan Marshall LLC (Marshall, Texas), VAZO series trade names from DowDuPont (Wilmington, Delaware), and CHEMEX series trade names from Hosung Chemex Co, Ltd. (Seoul, Korea), including CHEMEX 2EHPC, BND series, BPV series, CND70(IP), OND, TMPO, AND, and APV.

[0062] The acrylic adhesive composition contains 0% to no more than 10% by weight, at least about 1% by weight, no more than 5% by weight, no more than 3% by weight, about 1% to about 5% by weight, or even about 2% to about 4.5% by weight of a thermal initiator.

[0063] It may be useful to include more than one or even two photoinitiators in acrylic adhesive compositions.

[0064] Available photoinitiators include, for example, 2-hydroxy-2-methyl-1-phenyl-prop-1-one, 2,2-dimethoxy-1,2-diphenylethyl-1-one, 1-hydroxycyclohexylphenyl ketone, 2,4,6-trimethylbenzoyl-diphenylphosphine oxide, benzophenone, benzoin, benzoin ethers (e.g., benzoin methyl ether and benzoin isopropyl ether), substituted benzoin ethers (e.g., anisoin methyl ether), substituted acetophenones (e.g., 2,2-diethoxyacetophenone and 2,2-dimethoxy-2-phenylacetophenone), and substituted α-keto alcohols. Alpha-ketol (e.g., 2-methyl-2-hydroxypropiophenone), aromatic sulfonyl chlorides (e.g., 2-naphthalenesulfonyl chloride), photoactive oximes (e.g., 1-phenyl-1,2-propanedione-2-(O-ethoxycarbonyl)oxime), methyl benzoylformate, and mixtures thereof.

[0065] Suitable photoinitiators are available under various trade names, including, for example, the OMNIRAD series from IGM Resins (Waalwijk, The Netherlands), such as OMNIRAD 73 2-hydroxy-2-methyl-1-phenylpropanone; the DAROCUR series from BASF Corporation (Florham Park, New Jersey), such as DAROCUR TPO 2,4,6-trimethylbenzoyl-diphenylphosphine oxide; the IRGACURE series from BASF Corporation, such as IRGACURE 651 and IRGACURE TPO; the ESACURE series from IGM Resin (Waalwijk, Netherlands), such as ESACURE KB-1 benzildimethylketal; and the GENOCURE series from RAHN USA Corp (Aurora, Ilinois), such as GENOCURE BAPO and GENOCURE. TPO-L and GENOCURE MBF.

[0066] The acrylic adhesive composition contains 0% to no more than 10% by weight, no more than 5% by weight, no more than 3% by weight, 0.2% to about 5% by weight, or even 0.5% to 5% by weight of a photoinitiator.

[0067] additive

[0068] Acrylic adhesive compositions may contain a variety of additives, including, for example, adhesion promoters (e.g., silane adhesion promoters), antioxidants, rheology modifiers, inhibitors, defoamers, fluorescent whitening agents, antioxidants, dyes, pigments, and combinations thereof.

[0069] Available adhesion promoters include, for example, silanes, isocyanate-containing compounds, titanates, zirconates, phosphates, epoxy-containing compounds, hybrid monomers and oligomers, and combinations thereof. Examples of available epoxy-containing compounds include, for example, silsesquioxanes, epoxy silanes, epoxy resins (e.g., bisphenol A diglycidyl ether and bisphenol F diglycidyl ether), epoxy phenolic novolac resins, epoxy cresol novolac resins, alicyclic epoxy resins, and combinations thereof. Available epoxy silane adhesion promoters are available under the trade name SILQUEST series from Momentive Performance Materials Inc. (Waterford, New York), including SILQUEST A187 alkoxysilane epoxy adhesion promoter.

[0070] Additional materials

[0071] Acrylic adhesive compositions may also contain additional materials. These additional materials may be liquid or solid at room temperature. Additional materials include other polymers, oligomers and monomers (e.g., non-reactive (meth)acrylate polymers (i.e., without residual (meth)acrylate functional groups), vinyl acetate polymers, core-shell polymers, synthetic rubber polymers having carboxyl, amino, vinyl-(meth)acrylate, or epoxy functional groups, or combinations thereof (e.g., polybutadiene and butadiene-acrylonitrile copolymers), or any other compatible polymers, etc.) and plasticizers.

[0072] The available additional polymers are available under the trade name ELVACITE from Mitsubishi Chemical UK Ltd. and under the trade name DEGALAN from Roehm America LLC.

[0073] Method for manufacturing spiral wound filter housing

[0074] The present invention is characterized by a method of manufacturing a housing for a spiral wound membrane filter, comprising the steps of: obtaining an acrylate adhesive composition comprising a polyfunctional (meth)acrylate and an initiator; passing at least one continuous strand of reinforcing material through the acrylate adhesive composition; winding the continuous strand around the outer periphery along the entire length of the spiral wound membrane filter; and exposing the continuous strand of reinforcing material coated with the acrylate adhesive composition to an energy source at a time selected from during winding, after winding, and combinations thereof.

[0075] The invention is further characterized by a method of manufacturing a housing for a spiral wound membrane filter, comprising the steps of: obtaining an acrylate adhesive composition comprising a polyfunctional (meth)acrylate and a photoinitiator; passing at least one continuous strand of reinforcing material through the acrylate adhesive composition; winding the at least one continuous strand around the outer periphery of the spiral wound membrane filter along its entire length; and exposing the continuous strand of reinforcing material coated with the acrylate adhesive composition to an energy source at a time selected during winding, after winding, and a combination of both.

[0076] The method involves coating at least one continuous strand of reinforcing material with an acrylic adhesive composition. To improve the speed of the method, any number of strands can be coated and wound simultaneously (e.g., more than one strand, even 2 to 20, or even 2 to 10 strands). The method may optionally include removing excess acrylic adhesive composition immediately after coating, after winding, or after both.

[0077] The energy source can be selected from ultraviolet light, visible light, electron beam radiation, microwave radiation, heat, and combinations thereof.

[0078] Alternatively, the energy source can be selected from ultraviolet light, visible light, heat, or combinations thereof.

[0079] The invention will now be described through the following embodiments. Unless otherwise stated, all parts, ratios, percentages and amounts specified in the embodiments are by weight.

[0080] Example

[0081] Test program

[0082] The test procedures used in the examples include the following. Unless otherwise stated, all ratios and percentages are by weight. Unless otherwise stated, the procedures are performed at room temperature (i.e., an ambient temperature of approximately 20°C to approximately 25°C).

[0083] Test Sample Preparation Method

[0084] Prepare the sample as follows: Warm the oligomer at 60°C for 2 hours, then add it to a clean mixing container. Lower the top shear blade into the oligomer and turn it to "medium" for 10 minutes. Then weigh the monomer and slowly add it to the oligomer. Then mix the sample under medium-high shear for 2 hours or until homogeneous.

[0085] In a separate container, add the powdered photoinitiator to the diluent (monofunctional) monomer and place it under another mixer for 15 minutes. Then add the diluent monomer / photoinitiator mixture to the original container. Blend the combined mixture for 30 minutes. Add the second photoinitiator and mix for 15 minutes. Test the viscosity of the blend and add diluent monomer as needed.

[0086] Viscosity was tested according to ASTM D1084 Test Method B.

[0087] Shore D hardness was tested according to ASTM D2240.

[0088] Pour the liquid acrylic adhesive into a 5.08 cm (2 inch) x 5.08 cm (2 inch) weighing pan to a depth of 0.635 cm (0.25 inch). Then cure the sample under a UVA lamp for 30 seconds and allow it to cool before testing.

[0089] Moisture absorption is tested according to ASTM D570.

[0090] Pour 6 grams of liquid acrylic adhesive into a 50.8 mm diameter metal weighing pan. Then cure it under UVA for 30 seconds. Once cooled, remove it from the pan. The cured thickness should be at least 3.2 mm. Allow the sample to stand at room temperature for 24 hours before starting the test.

[0091] Tensile properties are tested according to ASTM D638 in the following manner.

[0092] Pour liquid acrylic adhesive into an ASTM D638 Type IV Teflon mold to prepare specimens approximately 2 mm thick. Cure the specimens under a UVA lamp for 30 seconds. Then allow them to stand under ambient conditions for at least 24 hours before testing. Use an Instron tensile tester set to an elongation rate of 5 mm / min. Report the average of 5–8 specimens.

[0093] Table 1

Claims

1. A spiral wound membrane filter including a housing, the housing comprising: a. Reinforcing materials, and b. An acrylic adhesive composition comprising a polyfunctional (meth)acrylate. When measured at 23°C according to ASTM D1084 Test Method B, the acrylate adhesive composition has a viscosity of not more than 10,000 cP.

2. The spiral wound membrane filter according to claim 1, wherein the acrylate adhesive composition comprises: i. 15% to 60% by weight of multifunctional (meth)acrylate oligomers, ii. 30% to 80% by weight of (meth)acrylate monomers, and iii. 0.2% to 5% by weight of photoinitiator.

3. The spiral wound membrane filter according to any one of the preceding claims, wherein the acrylate adhesive composition has a viscosity of not more than 2,500 cP when measured at 23°C according to ASTM D1084 Test Method B.

4. The spiral wound membrane filter according to any one of the preceding claims, wherein the acrylate adhesive composition has a viscosity of not more than 1,500 cP when measured at 23°C according to ASTM D1084 Test Method B.

5. The spiral wound membrane filter according to any one of the preceding claims, wherein the acrylate adhesive composition has a Shore D hardness of 60 to 100 as tested according to the Shore D hardness test method.

6. The spiral wound membrane filter according to claim 1, wherein the multifunctional (meth)acrylate is selected from (meth)acrylate oligomers, (meth)acrylate monomers, and combinations thereof.

7. The spiral wound membrane filter according to claim 2, wherein the multifunctional (meth)acrylate oligomer is selected from urethane acrylates, epoxy acrylates, polyester acrylates, acrylic acrylates, polyether acrylates, polybutadiene acrylates, and combinations thereof.

8. The spiral wound membrane filter according to claim 2, wherein the multifunctional (meth)acrylate oligomer comprises aliphatic urethane acrylate.

9. The spiral wound membrane filter according to claim 2, wherein the (meth)acrylate monomer comprises isoborneol acrylate monomer.

10. The spiral wound membrane filter according to claim 2, wherein the (meth)acrylate monomer comprises at least two (meth)acrylate monomers.

11. The spiral wound membrane filter according to claim 10, wherein the at least two (meth)acrylate monomers include monofunctional monomers and polyfunctional monomers.

12. The spiral wound membrane filter according to any one of the preceding claims, wherein the reinforcing material is a continuous glass fiber strand.

13. The spiral wound membrane filter according to any one of the preceding claims, wherein the acrylate adhesive composition is a single component having 100% solids.

14. A method for manufacturing the housing of a spiral wound membrane filter, comprising the following steps: a. Obtain an acrylic adhesive composition comprising a polyfunctional (meth)acrylate and an initiator, having a viscosity of not more than 10,000 cP when measured at 23°C according to ASTM D1084 Test Method B. b. Pass at least one continuous strand of reinforcing material through the acrylate adhesive composition. c. The continuous strands are wound around the outer periphery along the entire length of the spiral wound membrane filter, and d. Exposing the continuous strands of the reinforcing material coated with the acrylate adhesive composition to an energy source at a time selected from during winding, after winding, and combinations thereof.

15. The method of claim 14, wherein the continuous strands of the reinforcing material are glass fibers, and the energy source is selected from ultraviolet light, visible light, heat, and combinations thereof.

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