Ion Exchange Membrane Stack Curing Process
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Solution Overview
Problem
Existing membrane manufacturing processes are limited by low production rates due to lengthy curing times and high energy consumption, which can be costly to increase, and there is a need for a method to produce multiple membranes simultaneously while reducing energy requirements.
Innovation Solution
A continuous process where multiple membrane substrates are wetted with a curable liquid mixture and arranged in a stack with films, allowing simultaneous curing and separation, using an apparatus with substrate and film feeding devices, curing regions, and optional stack separating regions to produce multiple membranes efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the curing region length is increased to produce more membranes simultaneously, then productivity is improved, but the cost and energy consumption increase significantly
Solution Approach 1:
Multiple membrane precursors are stacked together and cured simultaneously in the same curing region, merging multiple production processes into one. This allows several membranes to be produced at the same time using the same curing energy, thereby increasing productivity without proportionally increasing energy consumption.
Solution Approach 2:
The process transitions from producing membranes sequentially in a linear fashion to producing multiple membranes in a stacked configuration (adding vertical dimension). This dimensional change allows parallel processing of multiple membranes through the same curing region, improving productivity without extending the curing region length.
2Productivity
If faster reaction rates are used by increasing temperature or catalyst activity to increase production rate, then productivity is improved, but energy consumption and process complexity increase
Solution Approach 1:
By stacking multiple membrane precursors and curing them together, the total curing energy is distributed across multiple membranes. This merging approach allows maintaining moderate temperatures and catalyst activity while achieving higher overall production rates, as the energy input is efficiently utilized across multiple simultaneous reactions.
3Productivity
If multiple membranes are produced simultaneously in a stack, then productivity is improved, but the device complexity increases due to additional feeding and separation mechanisms
Solution Approach 1:
The apparatus is divided into distinct functional modules: substrate feeding devices, film feeding devices, curing regions, and stack separating regions. This segmentation allows each component to perform a specific function, making the complex process of producing multiple membranes simultaneously more manageable and easier to implement by breaking down the overall system into manageable parts.
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
This method enables the production of two or more membranes simultaneously with reduced curing energy per unit area, potentially increasing production rates without significantly increasing curing time or energy consumption, and can modify existing lines to produce diverse membrane types.
Implementation Method 1
Polymerizable components in the liquid are polymerized thereby forming a reinforced polymer sheet
Implementation Method 2
The sandwich passes through a set of means, for example heaters, for curing the liquid
Data Source
AI summary
To make membranes, a plurality of membrane substrates are each wetted with a curable liquid mixture, arranged in a stack such that every pair of substrates are separated by at least one film, and moved simultaneously through a common curing region. Each wetted substrate sheet may be sandwiched between two films. After curing, the stack comprises two or more membranes with each pair of membranes separated by a film. An apparatus for making membranes comprises at least two substrate feeding devices, at least one film feeding device, one or more chemical wetting devices, a curing region, optionally, a stack separating region, and, optionally, a membrane binding or fusing region. Membrane production rate may be increased while the curing energy required per unit area of membrane is decreased. The method can make, for example, ion exchange membranes.