Membrane Element With Low-Melting Yarn Flowpath
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Solution Overview
Problem
Conventional membrane elements for membrane bioreactors require additional components like adhesive nets and spacer fabrics, increasing complexity and risking pore size distribution changes during backwashing, due to the need for separate bonding members and potential dope solidification in spacer fabric channels.
Innovation Solution
A membrane element comprising a filtration membrane joined to a flowpath member with a three-dimensional structure formed by low-melting point yarn, eliminating the need for separate bonding members by using the flowpath member's yarn to entangle with the filtration membrane during heating, thus reducing component count and preventing pore size distribution changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bonding members (adhesive nets) and spacer fabrics are used to join filtration membranes, then the filtration membrane can be securely bonded, but the device complexity increases and manufacturing precision may deteriorate due to dope solidification in spacer fabric channels
Solution Approach 1:
The patent merges the bonding member and flowpath member into a single integrated component. The flowpath member is constructed with a three-dimensional structure where coupling threads form internal spaces for permeate flow, eliminating the need for separate adhesive nets and spacer fabrics. This integration reduces component complexity while maintaining bonding reliability through the low-melting point yarn that bonds the filtration membrane directly to the flowpath member.
Solution Approach 2:
The flowpath member serves multiple functions simultaneously: it acts as a bonding member to secure the filtration membrane, provides a three-dimensional structure with internal spaces for permeate collection and backwashing flow, and eliminates the need for separate spacer fabrics. This multi-functionality reduces device complexity while maintaining all necessary capabilities.
2Reliability
If conventional bonding methods with separate adhesive nets are used, then the filtration membrane can be joined, but manufacturing precision deteriorates due to potential dope solidification in spacer fabric channels
Solution Approach 1:
The patent eliminates the separate spacer fabric component that could trap and solidify dope during manufacturing. By integrating the flow channels directly into the flowpath member's three-dimensional structure formed by coupling threads, the design prevents dope solidification issues while maintaining reliable joining through the low-melting point yarn bonding mechanism.
Solution Approach 2:
The patent extracts and eliminates the problematic spacer fabric component from the conventional design. By removing this separate element and integrating its flow channel function directly into the flowpath member structure, the design prevents the dope solidification issue that occurs when dope enters spacer fabric channels during manufacturing.
3Device complexity
If the filtration membrane is not fully fixed during backwashing, then the structure remains simple, but the membrane may bulge and contact adjacent membranes, reducing backwashing effectiveness
Solution Approach 1:
The patent integrates the bonding and flowpath functions into a single component that provides sufficient support to prevent membrane bulging during backwashing. The low-melting point yarn bonds the filtration membrane to the flowpath member's outer bonding surface, creating a structurally sound assembly that maintains membrane position without requiring additional support structures.
Solution Approach 2:
The flowpath member uses composite construction with low-melting point yarn for bonding surfaces and high-strength threads for structural integrity and flow channel formation. This composite approach allows the bonding surface to securely attach the filtration membrane while the three-dimensional coupling thread structure provides mechanical support to prevent bulging during backwashing operations.
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
Simplifies the membrane element manufacturing process by eliminating dedicated bonding members and prevents pore size distribution changes, ensuring effective filtration and backwashing without additional components or solidification issues.
Implementation Method 1
At least part of the threads forming the outer bonding surface is made of low-melting point yarn having a softening point lower than that of a material forming the filtration membrane
Implementation Method 2
the flowpath member and the filtration membrane thus arranged are heated to such a temperature that is equal to or higher than the softening point of the low-melting point yarn forming the bonding surface
Implementation Method 3
the low-melting point yarn of the bonding surface is softened and the resin of the low-melting point yarn is entangled with the filtration membrane, whereby the filtration membrane is joined to the bonding surface of the flowpath member
Data Source
AI summary
A membrane element includes a filtration membrane and a flowpath member joined thereto. The flowpath member is made of yarn arranged into a three-dimensional structure, and includes inner spaces through which a permeated liquid permeated through the filtration membrane flows, and an outer bonding surface joined to the filtration membrane. At least part of the yarn forming the outer bonding surface is a low-melting point yarn having a softening point lower than that of a material forming the filtration membrane, or the yarn forming the outer bonding surface is formed by twisting a plurality of constituent yarns, and at least one of the constituent yarns is a low-melting point yarn having a softening point lower than that of the material forming the filtration membrane.