Integrated Permeate Channel Membrane with 3D Spacer
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Solution Overview
Problem
Existing membrane technologies face challenges with poor adhesion of membrane layers to support structures, leading to limited backwash pressure, laborious module construction, and poor particle expulsion, particularly in micro- and ultrafiltration applications.
Innovation Solution
An integrated permeate channel membrane with a 3D spacer fabric and monofilament threads linking membrane layers, allowing for strong adhesion and efficient backwashing, and comprising hydrophilic filler materials and organic binder materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate constituents (membranes, spacers, support) are brought together to form membrane modules, then module construction is achieved, but construction becomes laborious and module integrity is compromised
Solution Approach 1:
The patent merges the spacer and support functions into a single integrated component. The permeable support structure combines the spacing function (maintaining membrane distance) and support function (providing mechanical strength) into one element, eliminating the need for separate spacer and support constituents. This integration directly reduces construction labor and simplifies the manufacturing process.
2Strength
If membranes are adhered to support structures, then adhesion is achieved, but adhesion strength is poor leading to limited backwash pressure
Solution Approach 1:
The patent employs a composite structure where the permeable support is made of porous material that mechanically interlocks with the membrane layers. The membrane adheres to the three-dimensional network of the permeable support, creating a composite material system with enhanced adhesion strength. This composite structure allows the membrane to withstand high backwash pressures up to 10 bar without detaching.
3Productivity
If conventional membrane structures are used, then filtration is achieved, but particle expulsion is poor requiring frequent cleaning
Solution Approach 1:
The patent applies local quality by creating a three-dimensional permeable support structure with varying pore sizes and distributions. The support structure has different local characteristics that facilitate particle expulsion - larger pores in certain regions allow trapped particles to be ejected during backwashing, while denser regions provide effective filtration. This localized structural variation enables both good filtration and effective particle expulsion.
4Productivity
If high sludge loads are maintained in MBR reactors, then biological degradation rates increase, but sludge production increases
Solution Approach 1:
The patent implements preliminary action by incorporating a pre-sintered porous layer on the membrane surface that provides initial particle trapping and pre-filtration. This preliminary filtration action prevents particle accumulation on the main membrane surface, allowing the system to maintain high sludge loads for enhanced biological degradation without proportionally increasing sludge production, as particles are intercepted earlier in the filtration process.
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 membrane can withstand high backwash pressures up to 10 bar, enabling long-term operation without frequent cleaning and maintaining module integrity, with improved particle expulsion and reduced operational costs.
Implementation Method 1
a novel membrane with an integrated permeate channel useable in different membrane applications such as Microfiltration, Ultrafiltration, MBRs, Pervaporation, Membrane distillation
Implementation Method 2
comprising hydrophilic filler materials and organic binder materials for enhanced performance
Data Source
AI summary
A membrane has a permeate channel including a 3D spacer fabric having an upper and a lower fabric surface (2,3) spaced apart by monofilament thread (4) at a predefined distance, the permeate channel being interposed between two membrane layers (12, 13), wherein the membrane layers are linked at a multitude of points with the upper and lower fabric surfaces to form an integral structure with a high bonding strength suitable for backflush operations. A method provides an integrated permeate channel membrane, including the steps of: —Providing a 3D spacer fabric having an upper and lower surface fabric (2,3) spaced apart by monofilament thread (4) at a predefined distance; and—Applying a membrane layer to both the upper and the lower surface fabric.