Coextruded Polyurethane PTFE Diffuser Membrane
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Flexible membrane diffusers in wastewater treatment face issues such as clogging from substances like fats, greases, and calcium compounds, as well as chemical degradation, leading to reduced efficiency and premature failure, and existing solutions like additional coating layers complicate manufacturing and increase costs.
Innovation Solution
A coextruded multi-layered flexible diffuser membrane is constructed using polyurethane and PTFE materials, where the base layer and coating layer are extruded simultaneously or sequentially, with optional primer or adhesive layers to enhance bonding and resistance to contaminants, allowing for controlled coating thickness and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating layer is applied to the membrane to resist contamination, then resistance to biological growth and material deposition is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the substrate layer and coating layer into a single coextruded membrane structure, integrating two previously separate manufacturing steps into one continuous process. This merging eliminates the need for separate coating application, curing, and cleaning steps, thereby reducing manufacturing complexity while maintaining the protective function of the coating layer
Solution Approach 2:
The patent uses composite materials by coextruding different polymer materials (substrate material and coating material) to form a multi-layer membrane structure. This composite approach provides both the mechanical properties of the substrate and the contamination-resistant properties of the coating material simultaneously, achieving improved reliability without additional manufacturing steps
2Ease of manufacture
If an uncured film is applied to a pre-cured substrate and cured together, then coating application is simplified, but both curing and bonding must be compromised due to conflicting time and temperature requirements
Solution Approach 1:
The patent changes the processing parameters by using thermoplastic materials that can be extruded in a molten state and then cooled to form the membrane structure. This parameter change allows both layers to be processed simultaneously under controlled temperature conditions, eliminating the conflict between curing time/temperature requirements and enabling optimization of both substrate formation and coating bonding
3Stability of the object's composition
If the substrate is cured before applying the film, then the substrate structure is stabilized, but cleaning the substrate becomes impossible and contaminants can interfere with bonding
Solution Approach 1:
The patent applies preliminary action by forming the coating layer on the substrate layer while both are in a thermoplastic, uncured state during coextrusion. This preliminary bonding occurs before any crosslinking or final stabilization, allowing contaminants to be removed by solvents or cleaning processes before the structure is finalized, thus enabling effective cleaning that would be impossible after curing
4Strength
If additional adhesive or bonding layers are used between substrate and coating, then bond strength is improved, but manufacturing steps and costs increase
Solution Approach 1:
The patent merges the substrate layer and coating layer into a single coextruded structure where the interface between layers is formed during the extrusion process itself. This integration eliminates the need for separate adhesive or bonding layers, reducing manufacturing steps while maintaining strong interlayer bonding through the coextrusion process and subsequent curing
Solution Approach 2:
The patent extracts the adhesive function from a separate layer and integrates it into the coextrusion process itself. The bonding between substrate and coating is achieved through the extrusion and cooling process rather than through a dedicated adhesive layer, thereby eliminating unnecessary manufacturing complexity while maintaining bond strength
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 provides a durable, efficient gas diffusion membrane that resists contamination and chemical degradation, maintaining performance and extending the membrane's lifespan while simplifying the manufacturing process and reducing costs.
Implementation Method 1
The coating has the ability to resist solvents and other chemicals and to resist adhesion of fat, grease, biological growth and other contaminants
Implementation Method 2
A coextruded multi-layered flexible diffuser membrane is constructed using polyurethane and PTFE materials, where the base layer and coating layer are extruded simultaneously or sequentially
Data Source
AI summary
A diffuser membrane and a method for manufacturing the same are provided. In the method for manufacturing, a first material is heated and extruded to form a base layer and a second material is heated and extruded to form a coating layer. The base layer and coating layer may be extruded substantially simultaneously in a coextrusion process. Accordingly, the coating may be applied to the base layer in a manner that optimizes the bonding between the two layers and provides the ability to control the thickness of the coating layer. Alternatively, the base layer is formed initially and the coating layer is subsequently formed thereover. The first and second materials have differing properties. The first material may comprise polyurethane and the second material may comprise polyurethane and PTFE.