Heat-Exchange Membrane Framing with Removable Film Reinforcement
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Solution Overview
Problem
Existing methods for bonding a porous resin film to a frame body for large-area heat-exchange membrane elements are inefficient, as they often result in membrane damage or reduced latent heat exchange rates due to contraction and resin pressure during injection molding, and require reinforcement with nonwoven fabrics that decrease moisture-permeable properties.
Innovation Solution
A solvent-soluble or solvent-disintegratable reinforcing layer is applied to the film, allowing for injection molding of a resin frame body without damaging the film, and then the reinforcing layer is removed with a solvent, enabling integral molding of the film to the frame body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a porous resin film is directly injection-molded without reinforcement, then the manufacturing process is simple, but the film contracts and loses its shape due to resin pressure and heat
Solution Approach 1:
A reinforcing layer is applied to the porous resin film before injection molding to prevent contraction and shape loss. This preliminary reinforcement allows the film to withstand the resin pressure and heat during molding without deforming, and the reinforcing layer is subsequently removed after molding to restore the film's original properties.
2Manufacturing precision
If a nonwoven fabric is used to reinforce the film, then the film maintains its shape during molding, but the latent heat exchange rate decreases due to reduced moisture-permeability
Solution Approach 1:
A soluble or disintegratable reinforcing layer serves as a temporary intermediary during the molding process. This layer provides the necessary mechanical support to maintain film shape during injection molding, then is completely removed using a solvent, leaving no residue that would block moisture pores and restore full latent heat exchange capability.
3Area of stationary object
If the film area is increased for large heat-exchange elements, then the heat exchange capacity is improved, but the film becomes difficult to bond to the frame body and may be swept away by resin pressure
Solution Approach 1:
The reinforcing layer is applied to the film before injection molding to provide temporary mechanical support. This allows large-area films to be successfully bonded to frame bodies during the molding process without being swept away by resin pressure, and the reinforcing layer is removed afterward to restore the film's original moisture-permeable properties.
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 allows for the successful bonding of films to frame bodies of any size, maintaining excellent dew condensation resistance and latent heat exchange properties, while preventing film damage and maintaining moisture-permeability.
Implementation Method 1
A solvent-soluble or solvent-disintegratable reinforcing layer is applied to the film, allowing for injection molding of a resin frame body without damaging the film, and then the reinforcing layer is removed with a solvent
Data Source
AI summary
A molded product including a film bonded to a resin frame is produced by a method including: 1) reinforcing the film with a solvent-soluble or solvent-disintegrable reinforcing layer; 2) inserting the reinforced film in an injection mold; 3) feeding a resin to the mold to attach a frame body to the reinforced film while injection molding the resin frame; and 4) treating the resulting injection molded product with a solvent to remove the reinforcing layer. This production process can establish a technique capable of bonding (integrally molding) the film solely to the frame body, regardless of the size of the film. The film may preferably be an expanded porous polytetrafluoroethylene film, and the moisture-permeable resin may preferably be combined with the expanded porous polytetrafluoroethylene film.