Membrane Filter Production Using Soft Adhesive Spacer
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Solution Overview
Problem
The existing methods for producing membrane filters are complex and costly, particularly due to the challenging handling and precise positioning of individual layers of hollow fiber membranes, which are often lengthy and require expensive robotic automation for accurate stacking and sealing.
Innovation Solution
A method that simplifies the production process by forming the membrane block directly with glue layers between rows of hollow fiber membranes, omitting the intermediary step of fabricating individual layers, and using a soft adhesive spacer to embed and secure the membranes within a header, allowing for automated production and reduced mechanical loading during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual layers of hollow fiber membranes are stacked and secured with glue, then the membrane block is formed, but the handling and positioning complexity increases requiring expensive robotic automation
Solution Approach 1:
The patent merges the individual membrane layers with the spacer structure by applying glue directly to the membrane surface during spacer formation. This integration eliminates the need for separate handling and positioning of individual layers, reducing production complexity while maintaining structural integrity.
Solution Approach 2:
The spacer is formed preliminarily with glue applied to the membrane surface before final assembly. This preliminary action secures the membrane layers in their correct positions during the spacer formation process itself, eliminating the need for subsequent complex positioning operations and robotic automation.
2Stability of the object's composition
If hollow fiber membranes are secured with rigid glue, then structural stability is improved, but mechanical loading increases reducing service life
Solution Approach 1:
The patent changes the physical parameters of the adhesive from rigid to soft/compliant material properties. This parameter change maintains structural stability through adequate bonding while reducing mechanical stress concentration on the hollow fiber membranes, thereby extending their service life under operational loading conditions.
Solution Approach 2:
The patent uses a composite approach combining the hollow fiber membranes with a soft adhesive material that provides both bonding strength and mechanical compliance. This composite structure achieves structural stability while accommodating operational deformations without damaging the membrane fibers.
3Strength
If multiple layers of glue are applied to secure membranes, then bonding strength is improved, but production time and complexity increase
Solution Approach 1:
The glue is applied preliminarily to the membrane surface during the spacer formation process itself, rather than in separate subsequent steps. This preliminary application ensures adequate bonding strength is achieved during the single spacer formation operation, eliminating the need for multiple separate gluing steps and reducing overall production time.
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 approach significantly simplifies the production process, reduces the complexity of handling individual layers, and enhances the service life of the membranes by using soft adhesives and highly viscous glues, facilitating easier integration and sealing, thus enabling cost-effective automation of membrane filter production.
Implementation Method 1
The hollow fiber membranes are adhesively secured to one another and/or to the header in the header
Implementation Method 2
introducing a liquid casting material between the spacer and the open ends so that the casting material encloses the hollow fiber membranes; curing the casting material to form the seal layer
Data Source
AI summary
A method for producing a membrane filter for filtering a liquid, wherein the membrane filter includes at least one header and at least one membrane block that is connected with the at least one header, wherein the at least one membrane block includes multiple rows of hollow fiber membranes arranged substantially parallel to one another, wherein each of the hollow fiber membranes includes an open end that connects to a permeate chamber in the at least one header and a filtrate is pullable from the permeate chamber during operation of the membrane filter, wherein the at least one membrane block includes a spacer at a distance from the open end, wherein the spacer connects the hollow fiber membranes with one another and keeps them apart, and wherein the hollow fiber membranes are enveloped by a seal layer between the spacer and the open end.