Flat Membrane Welding Pattern to Prevent Burnt Bit Retention

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Solution Overview

Problem

The existing flat membrane elements suffer from burnt bits retention in mesh-type projections during thermal welding, leading to poor appearance and waterproofness issues, and are difficult to clean effectively.

Innovation Solution

The flat membrane element features a thermal welding part with alternating small and large welding areas, formed by projections and recesses that are not surrounded by the hot projection, allowing easy removal of burnt bits and preventing them from sticking during thermal welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mesh-type hot projection is used for thermal welding, then sealing between the filtration membrane and filter plate is achieved, but burnt bits are retained in the recesses causing poor appearance and waterproofness

Engineering Contradiction:

Improvesealing integrityVSAvoidburnt bits retention

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional mesh-type hot projection design by using a solid-type hot projection without surrounding recesses. This inversion eliminates the trapping of burnt bits while maintaining thermal welding capability, as the hot projection directly contacts the filtration membrane and filter plate to create the sealing thermal welding part without creating recesses where burnt bits could be retained.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts and eliminates the recesses from the hot projection design. By removing the mesh structure and its surrounding recesses, the design prevents burnt bits from being trapped during thermal welding, thereby solving the waterproofness and appearance issues caused by burnt bits retention.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If mesh-type hot projection is used, then thermal welding sealing is achieved, but cleaning the hot plate becomes difficult and time-consuming

Engineering Contradiction:

Improvesealing integrityVSAvoidcleaning ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent inverts the mesh structure to a solid structure, eliminating the recesses that make cleaning difficult. The solid-type hot projection has a smooth surface without trapped corners, allowing burnt bits to be easily removed during cleaning operations, thereby improving ease of operation.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If burnt bits stick to the hot plate in recesses, then thermal welding can proceed, but burnt bits transfer to the membrane element causing poor appearance and low waterproofness

Engineering Contradiction:

Improvethermal welding processVSAvoidburnt bits transfer

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the recesses from the hot projection design. Without recesses, burnt bits cannot be trapped or retained on the hot plate during thermal welding, thereby preventing their transfer to the membrane element and eliminating appearance and waterproofness issues.

Inventive Principle:

Principle #2Taking out (Extraction)

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 configuration effectively prevents burnt bits from adhering to the membrane element, ensuring easy cleaning and maintaining sealing integrity.

Implementation Method 1

a hot projection provided on a hot plate is pressed onto the filter plate from above of the outer edge of the filtration membrane. This forms the thermal welding part so as to thermally weld the filtration membrane to the filter plate.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The thermal welding part is formed into square meshes. This provides sealing between the filtration membrane and the filter plate along the outer edge of the filtration membrane.

Methodology Applied

Scientific EffectThermal welding: Welding

Data Source

PatentUS12521679B2Flat membrane element and method for producing same

Publication Date: 2026.01.13 KUBOTA CORP

AI summary

The outer edge of a filtration membrane is thermally welded to a filter plate by a first thermal welding part. The first thermal welding part includes an outer boundary line disposed inside an outer edge of the filter plate and an inner boundary line disposed inside the outer boundary line. The outer boundary line has a plurality of first projected portions and first recessed portions that are alternately formed. The first projected portion projects toward the outer edge of the filter plate, and the first recessed portion is formed between the first projected portions and retracts in an inward direction A opposite to the outer edge of the filter plate.