Integrally Molded Manifold End Caps for Flat Sheet Membranes
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Solution Overview
Problem
Existing membrane filtration systems face issues with costly and prone-to-failure O-rings in end cap type systems and temperature-induced polyurethane swelling and brittleness in potted type systems, which hinder efficient replacement and reliability of flat sheet membranes.
Innovation Solution
A one-piece, integrally-molded manifold and end cap structure that eliminates O-rings and allows for individual membrane replacement, featuring a modular design with a patch system and flexible necks for secure membrane support, and an external frame module for enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If end cap type with O-rings is used, then individual flat sheet membranes can be replaced individually, but the system requires many O-rings which are costly and prone to failure
Solution Approach 1:
The invention removes O-rings entirely from the system by using a different sealing approach. The manifold is designed with integral sealing surfaces that directly contact the membrane edges, eliminating the need for O-rings while maintaining the ability to replace individual membranes.
Solution Approach 2:
The manifold structure is merged with the end caps into a single integral component. This unified structure provides both the collection function and the sealing function, eliminating separate sealing elements like O-rings while enabling individual membrane replacement through the design of removable membrane holders.
2Device complexity
If potted type with polyurethane sealant is used, then the structure is simplified, but the polyurethane swells and shrinks with temperature changes causing membrane damage
Solution Approach 1:
The invention changes the material parameter from polyurethane sealant to a rigid integral manifold structure made of corrosion-resistant material. This eliminates the thermal expansion and contraction issues of polyurethane while maintaining structural simplification through the integral design.
Solution Approach 2:
The manifold is constructed from composite or alloy materials that provide both structural integrity and resistance to thermal expansion. The integral design combines multiple functions into one piece that is resistant to temperature-induced dimensional changes.
3Device complexity
If potted type with polyurethane sealant is used, then the structure is simplified, but the brittle membrane flat sheets can be shattered due to expansion and contraction
Solution Approach 1:
The invention changes the sealing material from flexible polyurethane to a rigid integral structure that does not undergo significant dimensional changes with temperature. This eliminates the mechanical stress that causes brittle membrane failure while keeping the overall structure simple through integration.
4Ease of repair
If end cap type is used, then individual membrane replacement is enabled, but the amount of sealant required increases significantly
Solution Approach 1:
The invention removes the need for large amounts of sealant by using integral sealing surfaces built into the manifold structure. The sealing function is extracted from separate sealant applications and incorporated directly into the manifold's geometry, reducing sealant quantity to minimal amounts only where absolutely necessary.
Data Source
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AI summary
Silicon carbide flat sheet filtration membranes are supported on one piece manifold/end cap structures. Ends of a large number of the parallel flat plate membranes are fitted into elongated end cap slots that are part of a single molded manifold/end cap structure, such a structure being at each end of the series of membranes. In addition, a one piece external frame module can be provided to receive the gang of flat plate membranes with attached manifold/end caps. In the event of a damaged plate, the plate can be removed and replaced along with a special end cap repair section. This provides advantages over prior arrangements with individual end caps for each module or potting of the flat plates into a box or chamber.