Composite Filter Membrane Duct Network Resolves Flowability-Strength Trade-off
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Solution Overview
Problem
Existing composite filter membranes face challenges with low mechanical strength, particularly in thin filtration layers, and require high open surface area on the support layer for flowability, which compromises structural integrity and backwashability.
Innovation Solution
A composite filter membrane design featuring a semipermeable filtration layer, a support layer with through-holes, and an intermediate layer with series of ducts connected to the support layer's through-holes, allowing for improved flowability and structural integrity while maintaining backwashability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the support layer has high open surface area to improve flowability, then the flowability is improved, but the structural integrity of the support layer is weakened
Solution Approach 1:
The invention divides the evacuation function into two parts: through-holes in the support layer and ducts in the intermediate layer. This segmentation allows the support layer to have fewer through-holes (maintaining structural integrity) while the intermediate layer provides additional flow paths through its duct system, resolving the contradiction between flowability and structural strength.
Solution Approach 2:
The invention adds a vertical dimension to the flow path by creating ducts within the intermediate layer that connect to through-holes in the support layer. This three-dimensional duct network provides additional flow capacity without increasing the open surface area of the support layer, thereby maintaining structural integrity while improving flowability.
2Productivity
If the support layer has high open surface area to improve flowability, then the flowability is improved, but the available surface for bonding the filtration layer is reduced
Solution Approach 1:
The invention separates the flow evacuation function (through-holes in support layer) from the bonding function (support layer surface). By providing dedicated ducts in the intermediate layer for flow evacuation, the support layer can maintain a large bonding surface area without compromising flowability, as the ducts provide the necessary flow paths.
Solution Approach 2:
The intermediate layer acts as an intermediary between the support layer and filtration layer. Its duct system mediates the flow evacuation function, allowing the support layer to dedicate its full surface area to bonding while the intermediate layer handles the flow management through its duct network.
3Productivity
If the filtration layer is made thin to improve filtration performance, then the filtration performance is improved, but the mechanical strength of the filtration layer is reduced
Solution Approach 1:
The invention creates different local structures within the intermediate layer: ducts in regions corresponding to through-holes for flow evacuation, and bonding regions without ducts for mechanical attachment. This local differentiation allows thin filtration layers to be supported effectively where needed while maintaining high flowability where required.
Solution Approach 2:
The invention creates a composite structure with the filtration layer, intermediate layer, and support layer. The intermediate layer combines flow evacuation functionality (ducts) with bonding functionality (bonding regions), providing both mechanical support for thin filtration layers and efficient flow paths, thereby resolving the contradiction between thin layer performance and mechanical 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 design enhances flowability and pressure drop performance, reduces manufacturing time and costs, and strengthens the bonding between the support and filtration layers, enabling effective backwashing.
Implementation Method 1
an intermediate layer, wherein the intermediate layer is made from the first polymeric material and sandwiched between the filtration layer and the support layer, and therefore laid above the support layer, but under the filtration layer, which intermediate layer is solvent bonded to the support layer
Data Source
AI summary
The present invention relates to the field of composite membranes. More specifically, the present invention relates to a composite filter membrane comprising: a filtration layer, a support layer comprising at least one through-hole; and an intermediate layer sandwiched between said filtration layer and said support layer.