Fiber-Reinforced Plastic Membrane Containers for High-Pressure Separation
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Solution Overview
Problem
Existing membrane-based devices for separating pressurized liquid mixtures are heavy, expensive, and require robust, thick-walled tempered steel containers that are difficult to maintain and repair, especially in challenging environments like marine facilities, due to the high operational pressures exceeding 120 bar.
Innovation Solution
The use of lightweight plastic containers reinforced with fibers, such as epoxy resin or Kevlar, which are designed with integrated end elements and sealing mechanisms to ensure pressure-tightness without mechanical weakening, allowing for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tempered steel containers are used to withstand high pressures, then operational safety and pressure-tightness are ensured, but weight and production cost increase significantly
Solution Approach 1:
The patent applies composite materials by combining plastic as the base material with fiber reinforcement (such as glass fibers, carbon fibers, or aramid fibers) to create a container that achieves both lightweight properties and high pressure resistance. This composite structure allows the container to withstand operational pressures exceeding 120 bar while reducing weight compared to solid tempered steel construction.
Solution Approach 2:
The patent changes the material parameter from traditional metal to plastic-based composite, fundamentally altering the weight-to-strength ratio. By optimizing the fiber content and type within the plastic matrix, the container achieves the necessary mechanical strength for high-pressure operation while maintaining significantly reduced weight.
2Reliability
If tempered steel containers are used to ensure pressure-tightness, then operational safety is maintained, but production cost increases
Solution Approach 1:
The patent uses plastic-based composite materials that are generally more cost-effective than tempered steel, particularly in terms of production and processing costs. The plastic matrix can be molded into complex geometries through injection molding or other forming processes, reducing manufacturing complexity and cost compared to metal fabrication.
Solution Approach 2:
By changing from metal to plastic composite materials, the patent leverages the inherent cost advantages of plastics in terms of material cost and ease of processing. The fiber reinforcement maintains the necessary mechanical properties while the plastic base material provides cost efficiency.
3Strength
If thick-walled tempered steel containers are used, then pressure resistance is achieved, but ease of repair and maintenance is reduced
Solution Approach 1:
The patent employs modular construction with separate fiber reinforcement layers and plastic matrix components that can be independently replaced or repaired. The segmented composite structure allows for easier maintenance compared to solid steel containers, as damaged sections can be targeted for repair without affecting the entire container structure.
Solution Approach 2:
The composite plastic-fiber structure allows for repair techniques that differ from metal repair, enabling the use of repair patches, resin injection, or component replacement that is more adaptable to maintenance scenarios. The plastic material can be chemically bonded to repair sections, providing reliable repairs that maintain pressure-tightness.
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 plastic containers significantly reduce weight and production costs while maintaining operational safety, enabling broader applications and easier maintenance in harsh environments.
Implementation Method 1
a device for filtering and separating liquid mixtures using a membrane
Implementation Method 2
the transportation of the liquid mixtures that are to be separated must take place via or through the membrane at very high pressures, e.g. in a range exceeding 120 bar
Implementation Method 3
the container must be robust enough that it can withstand these pressures during the conveyance of the liquid mixture
Implementation Method 4
the plastic is made of a plastic that is suitable for withstanding extremely high pressures
Implementation Method 5
the pressure-tight container is made of a plastic that is suitable for withstanding extremely high pressures... the plastic can be reinforced with fibers
Data Source
AI summary
A device for filtering and separating pressurized liquid mixtures by means of a membrane includes a substantially pressure-tight container in which the membranes are accommodated in a pressure-tight manner. The container has at least one intake for the mixture, as well as at least one outlet for the permeate separated from the mixture by means of the membranes, and at least one outlet for the retentate, also referred to as a concentrate. The pressure-tight container is made of plastic.