Corrugated spacer disc assembly for reverse osmosis system

Abstract

The present invention relates to a corrugated spacer disc for reverse osmosis (RO) systems, designed to enhance fluid flow dynamics, reduce pressure drop, and improve structural strength. The disc- shaped spacer element features a series of corrugations along its peripheral surface, which increase the surface area, allowing for a higher volume of water passage while ensuring uniform distribution across the membrane. The unique corrugated geometry also reduces hydraulic resistance, minimizing pressure drop and lowering energy consumption. Additionally, the enhanced flow dynamics help prevent fouling, scaling, and biofilm accumulation, thus improving filtration efficiency and extending the lifespan of the membrane. The invention is suitable for various RO applications, including desalination, wastewater treatment, and potable water production.

Description

[0001] CORRUGATED SPACER DISC ASSEMBLY FOR REVERSE OSMOSIS SYSTEM FIELD OF THE INVENTION

[0002] The present invention relates to the field of reverse osmosis (RO) technology, specifically to the advanced spacer elements used in RO membrane module. More particularly, the present invention relates to a corrugated spacer disc that improves fluid flow dynamics, reduces pressure drop, and enhances structural strength within reverse osmosis system.

[0003] BACKGROUND OF THE INVENTION

[0004] Reverse osmosis (RO) is a widely used water purification technology that removes dissolved salts, contaminants, and impurities from water by forcing it through a semipermeable membrane under pressure. RO systems are extensively employed in applications such as desalination, wastewater treatment, industrial water processing, and potable water production.

[0005] In an RO system, the membrane is typically arranged in spiral-wound or stacked configurations. These membranes allow the water molecules to pass through them while rejecting dissolved salts and contaminants. To maintain the efficiency and longevity of these membranes, spacer elements are used between membrane layers. These spacers maintain a uniform distance between the membranes to facilitate the flow of feed water and brine, and prevent membrane fouling or damage caused by direct contact.

[0006] Over the years, various spacer designs have been developed to enhance the performance of RO systems. The most widely used design includes net-type spacers, woven mesh spacers, and spiralwound spacers. Among them flat or mesh-like geometry is mostly used in traditional spacer’s designs. These spacers are typically made of polymer materials and are designed with intersecting strands to form flow channels for water distribution. While these designs have been effective in supporting membrane structures and enabling water flow, they suffer from several inherent limitations which are described herein below:

[0007] Firstly, the flat periphery of traditional spacers restricts the flow channels, leading to increased hydraulic resistance. This results in a higher pressure drop across the RO module, necessitating greater energy input to maintain the required flow rates, thereby increasing operational costs. Additionally, flat designs often limit the volume of water that can pass through the system, leading to inefficient water distribution and uneven utilization of the membrane surface.Furthermore, conventional flat spacers are prone to deformation or collapse under high-pressure conditions. Thus, compromise their ability to maintain proper membrane spacing and flow dynamics. Thus, the lack of optimal flow dynamics in flat spacers allows for the accumulation of fouling agents, scaling, and biofilms. These issues reduce the operational efficiency and lifespan of the membranes and increase the need for frequent maintenance. Due to the combination of high pressure drop and suboptimal flow dynamics, traditional spacer designs consume more energy during operation, making the systems less cost-effective in the long term.

[0008] To address these challenges, there is a need for an advanced spacer design that enhances water flow dynamics, reduces pressure drop, improves structural strength, and minimizes fouling and scaling.

[0009] Therefore, to solve the limitation associated with conventional spacer elements. The present invention discloses a unique corrugated spacer disc assembly. The said corrugated spacer disc assembly represents the first-ever corrugated design in Disc RO Technology. The corrugated shape increases the flow volume for water passage and provides uniform water distribution across the membrane. This innovative geometry not only reduces water droplet pressure but also enhances structural strength, allowing the disc to withstand high-pressure conditions without deformation. OBJECTIVES OF THE INVENTION

[0010] The primary objective of the present invention is to provide a spacer disc assembly for reverse osmosis (RO) system that ensures uniform water distribution, increases flow volume, and eliminates dead zones within the RO module.

[0011] Another objective of the present invention is to provide a unique spacer geometry that minimizes hydraulic resistance, thereby reduces pressure drop across the reverse osmosis module and lowers energy consumption during operation.

[0012] Another objective of the present invention is to provide a corrugated spacer disc assembly that reduces the accumulation of bio-fouling, scaling, and debris on the membrane surface by optimizing the flow channels and promoting turbulence in the water stream.

[0013] Another objective of the present invention is to provide a corrugated spacer disc assembly that is easy-to-clean during maintenance cycles thus effectively removing the residual fouling and scaling.Another objective of the present invention is to provide a compact and efficient disc-shaped spacer element that maximizes the active filtration area while maintaining adequate spacing for fluid flow.

[0014] Further objectives, advantages, and features of the present invention will become apparent from the detailed description provided herein below, in which various features, and functionalities of the disclosed invention are illustrated by way of the following examples.

[0015] SUMMARY OF THE INVENTION

[0016] For the purpose of summarizing this invention, the present invention discloses a disc-shaped spacer elements designed for use in reverse osmosis (RO) system. The innovative spacer is designed to optimize fluid flow dynamics, ensuring uniform water distribution, and minimizing the formation of dead zones. The design reduces fouling, scaling, and pressure drop, thereby enhancing filtration efficiency and lowering energy consumption. Additionally, the spacer facilitates effective cleaning, maintains structural stability under high-pressure conditions, and extends the operational lifespan of RO membranes.

[0017] According to the invention, we have found that the unique corrugated geometry of the disc shaped spacer element provide significant advantages over the commercially available spacers.

[0018] More specifically, the disc shaped corrugated spacer assembly according to the present invention has been found to improve the fluid flow characteristics, resulting in higher efficiency of the associated membrane module, as a result of a lower pressure drop across the membrane.

[0019] The corrugated design creates flow channels that optimize water movement within the system. This improvement in fluid flow dynamics helps to prevent the accumulation of fouling agents, scaling, and biofilms by promoting turbulence and more uniform water flow across the membrane surface. As a result, the operational lifespan of the membrane is extended, and maintenance cycles are simplified.

[0020] In conclusion, the disclosed corrugated spacer disc assembly represents a significant advancement in reverse osmosis technology, addressing critical issues faced by conventional spacer elements. Its innovative design improves fluid flow dynamics, reduces pressure drop, enhances structural strength, and minimizes fouling and scaling, resulting in higher efficiency and longer service life for RO systems. This invention offers both technical and economic benefits, making it a valuable solution for various applications in water purification, desalination, and industrial water processing.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present disclosure illustrated in the accompanying non-limiting drawings, throughout which like reference letters include corresponding parts in the various figures.

[0022] Fig. 1 illustrates a top view of the corrugated spacer disc assembly according to an embodiment of the present invention.

[0023] Fig. 2 illustrates a top cross-sectional view of the corrugated spacer disc assembly, according to another embodiment of the present invention.

[0024] Fig. 3 illustrates a bottom view of the corrugated spacer assembly according to another embodiment of the present invention.

[0025] Fig. 4 illustrates a bottom cross-sectional view of the corrugated spacer assembly according to another embodiment of the present invention.

[0026] Fig. 5 illustrates an exploded view of the corrugation provided at the periphery of the spacer disc assembly according to another embodiment of the present invention.

[0027] DETAILED DESCRIPTION OF THE INVENTION

[0028] The following detailed description refers to the accompanying drawings that show, by way of illustration, specific details, and embodiments in which the invention may be practiced. These embodiments are described in sufficient details to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, and logical changes may be made without departing from scope of the invention. The various embodiments are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. Unless otherwise specifically defined herein, all terms to be given their broadest possible interpretation including meaning implied from the specification as well as meanings understood by those skilled in the art and / or as defined in dictionaries, treaties, etc.

[0029] In the specification, the term “comprising” shall be understood to have a broad meaning similar to the term “including” and will be understood to imply the inclusion of a stated integer or step or group of integers or step but not the exclusion of any other integers or step or group of integers or steps. This definition also applies to variations on the term “comprising” such as “comprise” and comprises”. In order that the invention may be readily understood and put into practical effect,particular embodiments will now be described by way of examples and not limitations, and with reference to the figures. It will be understood that any property described herein for a specific system may also hold for any system described herein. Furthermore, it will be understood that for any system or method described herein, not necessarily all the components or steps described must be enclosed in the system or method, but only some (but not all) components or steps may be enclosed.

[0030] According to an embodiment the present invention relates to a disc-shaped spacing element, particularly designed for use in reverse osmosis (RO) systems. The disclosed invention is a significant advancement in the field of water purification and filtration technology, specifically addressing the limitations observed in the prior art spacer elements.

[0031] Referring now to figure 1 illustrating a top view of the corrugated spacer assembly according to an embodiment of the present invention. The assembly features a disc-shaped design with a series of radially arranged corrugations extending from the disc opening (1) to the periphery (2). The corrugations are systematically spaced to optimize water flow distribution across the membrane surface. The central region of the spacer includes mounting features to facilitate secure placement within the reverse osmosis system. The corrugated design enhances structural integrity, increases the surface area, and minimizes pressure drop, contributing to improved filtration efficiency and reduced operational costs. Additionally, the uniform channel distribution helps to prevent membrane fouling by promoting turbulence and reducing dead zones within the system.

[0032] Referring now to figure 2 illustrating a top cross-sectional view of the corrugated spacer assembly according to another embodiment of the present invention. The said spacer element which is in discshaped structure, featuring a series of corrugations (3) along its peripheral surface. These corrugations (3) are meticulously designed to optimize water flow while maintaining structural integrity. The corrugated geometry increases the overall surface area, facilitating a higher volume of water passage. Additionally, the corrugations contribute to uniform distribution of water across the disc, eliminating dead zones and enhancing the filtration process.

[0033] Referring now to Fig. 5, illustrating the detailed structure of the corrugation pattern at the periphery of the spacer disc assembly, according to another embodiment of the present invention. The corrugation features a wave-like profile with alternating peaks (4) and troughs (5), which arestrategically designed to optimize fluid dynamics within the reverse osmosis (RO) membrane system.

[0034] The corrugated profile enhances turbulence in the water flow, preventing the formation of stagnant zones and reducing the risk of membrane fouling. Additionally, the unique undulating structure facilitates efficient water distribution by creating multiple flow paths, ensuring uniform pressure across the membrane surface. The design also incorporates rounded edges at the peaks and troughs, which minimize shear stress on the membrane while maintaining structural integrity

[0035] The novelty of the present invention lies in the corrugated shape provided at the periphery of the spacer element. Unlike the traditional flat spacer assemblies, which measure approximately 2.0 mm in thickness, the innovative corrugated design of the disclosed spacer element measures only 1.5 mm. This reduction in thickness, coupled with the corrugated structure, provides extra space for water flow, thus effectively reducing the pressure drop across the system. The enhanced flow dynamics achieved through this design significantly improve the energy efficiency and operational performance of reverse osmosis systems.

[0036] The spacer element is manufactured using high-quality, durable materials known for their strength, flexibility, and resistance to wear and tear. The material selection ensures that the disc maintains its structural integrity under high-pressure conditions typically encountered in RO systems. In a preferred embodiment of the present invention, the corrugated spacer disc assembly is manufactured using delrin material which a high-performance plastic known for its strength, stiffness, dimensional stability, and self-lubricating properties. The self-lubricating properties help in reducing the frictional wear and prolong the service life of the spacer element.

[0037] In another embodiment of the present invention, the spacer element is specifically designed with self-lubricating properties to enhance its operational efficiency and durability. The material used for manufacturing contains inherent self-lubricating characteristics, such as low coefficients of friction, which minimize frictional wear during prolonged operation. This feature is particularly beneficial in high-pressure environments, where consistent movement or interaction with other components can cause significant wear and tear. By reducing friction, the self-lubricating properties not only extend the service life of the spacer element but also contribute to smoother operation and reduced maintenance requirements. This embodiment further highlights the advanced engineering and material selection involved in the disclosed invention.According to another embodiment of the present invention, the corrugated design of the spacer disc creates additional voids or channels within the system. These voids allow suspended particles in the fluid to settle or pass through without clogging or obstructing the flow path. This feature enhances the operational efficiency of the reverse osmosis (RO) system by preventing the accumulation of debris and reducing the likelihood of membrane fouling.

[0038] In essence, the corrugations optimize the available space within the spacer disc, ensuring better flow distribution and minimizing pressure drop while providing additional capacity to accommodate suspended matter.

[0039] According to another embodiment of the present invention, the corrugations on the spacer element are designed with variable depth and width to cater to specific flow rate requirements. The variation in the depth and width allows the spacer to be used in various applications demanding precise flow dynamics and reduced pressure drops.

[0040] In another embodiment, the corrugated design includes integrated micro-channels that guide water flow more effectively, ensuring uniform distribution across the membrane surface and reducing localized pressure variations.

[0041] In another embodiment, a multi-layered spacer element configuration is disclosed, where multiple corrugated discs are stacked together to enhance overall structural strength and accommodate higher flow volumes without compromising efficiency.

[0042] In another embodiment of the present invention, the spacer is manufactured using composite materials that reduce the overall weight of the element while retaining strength and flexibility, making it suitable for portable or modular RO systems.

[0043] The foregoing description explains the structure and the principles of operation of the preferred embodiment of the invention. Various changes and the modifications may be made of course, without departing from the scope of the present invention.

Claims

CLAIMSWe Claim:

1. A corrugated spacer disc for reverse osmosis (RO) systems, comprising:a) a disc-shaped spacer element featuring a series of corrugations along its peripheral surface, wherein the corrugations increase the surface area of the spacer;b) the corrugated geometry providing enhanced structural strength to the spacer, enabling it to withstand high-pressure conditions without deformation;c) the corrugated design facilitating increased water flow volume, reducing hydraulic resistance, and minimizing pressure drop across the RO system.

2. The spacer disc as claimed in claim 1, wherein the increased surface area provides uniform water distribution across the membrane surface, eliminating dead zones and enhancing filtration efficiency.

3. The spacer disc as claimed in claim 1, wherein the corrugations create flow channels that promote turbulence in the water stream, reducing the accumulation of fouling agents, scaling, and biofilms on the membrane surface.

4. The spacer disc as claimed in claim 1, wherein the corrugations are configured to create additional volumetric space within the disc, thereby providing suspended matter with an expanded area for distribution, reducing the risk of clogging, and enhancing the operational efficiency and durability of the membrane system.

5. The spacer disc as claimed in claim 1, wherein the spacer element comprises self-lubricating properties to reduce frictional wear during operation.

6. The spacer disc as claimed in claim 1, wherein the corrugated design includes integrated microchannels that further guide water flow, ensuring more uniform distribution across the membrane surface and reducing localized pressure variations.

7. A multi-layered spacer disc assembly for reverse osmosis (RO) systems, comprising a stack of multiple corrugated spacer discs as claimed in claim 1, wherein the stacked discs enhance structural strength and accommodate higher flow volumes without compromising efficiency.

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