Convertible Hollow Fiber Membrane Bundle for Dual Flow Modules

Solution Overview

Problem

Manufacturers of gas separation membrane modules need separate inventory and manufacturing lines for cross-flow and countercurrent-flow configurations, leading to a large footprint and significant investment, which is inefficient and costly.

Innovation Solution

A convertible hollow fiber membrane bundle that can be manufactured into modules with either cross-flow or countercurrent-flow configurations, using a porous support tube, cured resin tubesheets or nubs, and collection tubes with specific orifices and seals, allowing for flexible conversion between configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manufacturers maintain separate inventory and manufacturing lines for cross-flow and countercurrent-flow configurations, then each configuration can be produced with optimized performance, but the facility footprint and inventory investment become very large

Engineering Contradiction:

Improveconfiguration-specific performanceVSAvoidfacility footprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The hollow fiber membrane bundle is designed with universal features that allow it to be converted into either cross-flow or countercurrent-flow module configurations. The bundle includes hollow fiber membranes arranged around a porous support tube with cured resin tubesheets at both ends, and the second end is configured to accept either a cured resin nub or a cured resin tubesheet. This universal design enables a single bundle type to serve multiple flow configuration purposes, eliminating the need for separate manufacturing lines and inventory for different configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If manufacturers maintain separate inventory and manufacturing lines for cross-flow and countercurrent-flow configurations, then each configuration can be produced with optimized performance, but the inventory investment becomes significant

Engineering Contradiction:

Improveconfiguration-specific performanceVSAvoidinventory

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The hollow fiber membrane bundle is designed with universal features that allow it to be converted into either cross-flow or countercurrent-flow module configurations. The bundle includes hollow fiber membranes arranged around a porous support tube with cured resin tubesheets at both ends, and the second end is configured to accept either a cured resin nub or a cured resin tubesheet. This universal design enables a single bundle type to serve multiple flow configuration purposes, eliminating the need for separate manufacturing lines and inventory for different configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If a single bundle type is used for both cross-flow and countercurrent configurations, then manufacturing complexity and inventory are reduced, but the conversion process requires additional steps

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidconversion process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The hollow fiber membrane bundle is pre-configured with cured resin tubesheets at both ends during manufacturing, and the second end is prepared to accept either a cured resin nub or a cured resin tubesheet. This preliminary preparation of the bundle structure allows for straightforward conversion between configurations by simply changing the component at the second end, rather than requiring complex reconfiguration processes. The pre-established universal structure minimizes the additional steps needed for conversion.

Inventive Principle:

Principle #10Preliminary action

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

Reduces manufacturing complexity, inventory, and facility footprint by enabling the production of both configurations using a single type of bundle, improving efficiency and reducing downtime while maintaining high performance.

Implementation Method 1

a first gas stream to be separated by the hollow fiber membranes is introduced into the hollow fiber membranes

Methodology Applied

Scientific EffectSelective permeation: Semipermeable Membrane

Implementation Method 2

the collection tube has a plurality of orifices formed in an outer circumferential surface of the collection tube

Methodology Applied

Scientific EffectPressure-driven flow: Pressure Gradient

Data Source

PatentUS12508549B2Gas separation membrane bundle with convertible flow configurations

Publication Date: 2025.12.30 LAIR LIQUIDE SA POUR LETUDE & LEXPLOITATION DES PROCEDES GEORGES CLAUDE

AI summary

A hollow fiber membrane bundle useful for manufacturing a wide variety of hollow fiber membrane modules having different flow configurations includes hollow fiber membranes arranged around a porous support tube, a cured resin tubesheet formed at first end of the bundle, and either a cured resin nub or a cured resin tubesheet formed at a second end of the bundle. The bore(s) of the hollow fiber membranes are open at a face of the tubesheet adjacent the first end of the bundle. The tubesheet has an annular structure that encapsulates the hollow fiber membranes and the porous support tube at the first end of the bundle but which does not completely block a bore of the porous support tube, wherein the collection tube has a plurality of orifices formed therein at least at positions adjacent the nub.