Additive Manufacturing of Self-Supporting Membranes for Dual-Flow Gas Exchangers
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Solution Overview
Problem
Existing dual-flow gas exchangers face limitations in energy efficiency due to restricted thermal and mass transfer mechanisms, and their assembly processes are complex and prone to pressure losses.
Innovation Solution
A method for manufacturing self-supporting membranes with a holding structure using additive manufacturing, where the membrane is glued to the structure, allowing for simplified assembly and reduced pressure losses by conforming to the topology of the shaping support, eliminating the need for elongated plating elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If breathable membranes are used to enable thermal and mass transfer, then energy efficiency is improved, but assembly complexity increases due to the need for elongated plating elements
Solution Approach 1:
The patent combines the membrane fixation function with the structural support function by integrating elongated plating elements that simultaneously serve as both structural supports and membrane anchors. This merging eliminates the need for separate fixation mechanisms and simplifies the assembly process while maintaining the breathability and thermal transfer efficiency of the membrane.
Solution Approach 2:
The elongated plating elements are pre-formed with specific geometric features (such as hooks or anchoring structures) that enable automatic membrane retention during assembly. This preliminary preparation of the plating elements allows for simplified installation where the membrane is naturally retained by the plating structure without requiring additional fixation steps.
2Reliability
If elongated plating elements are used to fix membranes, then membrane retention is improved, but pressure losses increase due to obstruction of gas flow
Solution Approach 1:
The plating elements are designed with localized anchoring features only at specific positions where membrane fixation is required, rather than being continuous obstructive structures. The geometric features (hooks, anchors) are concentrated at discrete locations along the plating elements, allowing gas flow to pass freely through the channels while maintaining secure membrane retention at critical points.
Solution Approach 2:
The plating elements incorporate curved or rounded geometric features instead of sharp edges or protruding structures. This curvature allows gas flow to follow the contours of the plating elements with minimal turbulence and pressure loss, while the curved anchoring features effectively retain the membrane through friction and geometric interlocking.
3Ease of manufacture
If membranes are made flexible to conform to support topology, then manufacturing simplicity is improved, but structural strength decreases
Solution Approach 1:
The patent employs composite membrane structures combining flexible polymer layers with reinforcing elements (such as embedded mesh, layered construction, or hybrid material composition). This composite approach maintains the flexibility needed for conforming to support topology during manufacturing while providing enhanced structural strength to withstand operational pressures and mechanical stresses.
Solution Approach 2:
The membrane is designed as a thin film structure with optimized thickness and material properties that provide sufficient flexibility for conforming to the support structure during assembly, while the film's inherent tensile strength and the confining pressure from the plating elements maintain structural integrity during operation. The thin film design allows easy manipulation and fitting while the system pressure keeps it taut and strong.
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
This approach enhances the assembly efficiency of dual-flow gas exchangers, reduces pressure losses, and improves energy transfer efficiency by allowing flexible membrane conformation and direct adhesion to the shaping support.
Implementation Method 1
the membrane is held on the front face of the shaping support by suction so that said membrane conforms to the shape of the front face during the execution of step a)
Implementation Method 2
said photopolymerizable material, projected, is then hardened by exposure to at least one source of ultraviolet radiation
Data Source
Figure 1~2c
Figure 3a~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a heat exchange element of a heat exchanger, the method comprising: a) positioning a membrane (10) on a front face of a forming support, the membrane (10) conforming to the shape of said front face; b) forming, by additive manufacturing, a retaining structure adhering to a free face of the membrane (10); c) removing the forming support so as to release the heat exchange element formed by the membrane (10) and the retaining structure.