Membrane Panel Assembly with Adhesive-Free Bonding for Energy Recovery
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Solution Overview
Problem
Existing energy recovery assemblies face performance issues due to improper membrane adhesion, leading to air leakage, pressure drop, and reduced effectiveness, while adhesive use increases costs and emits harmful VOCs, and wrapping techniques are labor-intensive and prone to leaks.
Innovation Solution
The integration of membrane sheets with outer frames without adhesives, using injection-molding, ultrasonic bonding, or laser-bonding to secure the membrane sheets directly to the frames, forming a sealed energy exchange assembly that transfers sensible and latent energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to secure the membrane to the spacer, then the membrane adhesion is improved, but the cost increases and harmful VOCs are emitted
Solution Approach 1:
The patent removes the adhesive substance from the system entirely by using a mechanical interlocking structure where the spacer has protrusions that fit into recesses in the membrane, eliminating VOC emissions while maintaining secure attachment
Solution Approach 2:
The spacer acts as an intermediary component with a dual function: it provides structural support and creates a mechanical interlocking connection through its protrusion-recess geometry, replacing the need for adhesives
2Reliability
If adhesives are used to secure the membrane to the spacer, then the membrane adhesion is improved, but the cost and labor increase
Solution Approach 1:
The patent eliminates the adhesive application step from the manufacturing process, reducing both material costs and labor requirements while maintaining reliable membrane attachment through mechanical interlocking
Solution Approach 2:
The spacer and membrane are designed to self-assemble through their complementary geometric features, allowing workers to simply snap the components together without requiring skilled adhesive application techniques
3Reliability
If excessive adhesive is used to secure the membrane to the spacer, then the membrane adhesion is improved, but the area available for heat and moisture transfer is reduced
Solution Approach 1:
By removing adhesives entirely and using a mechanical interlocking system with minimal contact points, the patent maximizes the membrane surface area available for energy and moisture transfer while maintaining secure attachment
Solution Approach 2:
The mechanical interlocking features are localized to specific protrusion and recess areas, allowing the majority of the membrane surface to remain exposed and functional for heat and moisture transfer
4Ease of manufacture
If wrapping techniques are used to assemble the energy recovery assembly, then the cost is reduced and membrane waste is minimized, but the process is labor intensive and leaks occur at edges
Solution Approach 1:
The patent replaces the wrapping mechanical system with a snap-fit mechanical interlocking system using protrusions and recesses, eliminating the need for labor-intensive wrapping while ensuring leak-free seals through precise geometric engagement
5Ease of manufacture
If wrapping techniques are used to assemble the energy recovery assembly, then the cost is reduced, but the process is labor intensive
Solution Approach 1:
The patent removes the time-consuming wrapping process entirely and replaces it with a quick snap-fit assembly operation, significantly reducing labor time while maintaining cost-effectiveness
Solution Approach 2:
The components are designed to self-assemble through their geometric features, allowing rapid installation without requiring skilled labor or complex tools
6Reliability
If tape is used to seal the seam in wrapping techniques, then the seam is sealed, but the pore structure of the membranes is blocked and moisture transfer is reduced
Solution Approach 1:
The patent eliminates the need for tape sealing by designing a leak-free mechanical interlocking system where the protrusion-recess connection inherently prevents air and moisture leakage without blocking membrane pores
Solution Approach 2:
The spacer protrusions serve as intermediaries that create sealed pathways for air and moisture flow while maintaining the structural connection, allowing transfer without blockage
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 enhances the performance and reduces costs by eliminating adhesive-related issues, minimizing VOC emissions, and simplifying the assembly process while maintaining efficient energy transfer.
Implementation Method 1
Heat and moisture are transferred between the two airstreams through the membrane layers
Implementation Method 2
The amount of moisture transferred in the core is generally governed by a humidity difference and convective mass transfer coefficients of the two air streams
Implementation Method 3
The membrane sheet may be integrated with the outer frame without an adhesive. The outer frame may be injection-molded around edge portions of the membrane sheet
Implementation Method 4
Alternatively, the membrane sheet may be ultrasonically bonded to the outer frame
Implementation Method 5
In at least one other embodiment, the membrane sheet may be laser-bonded to the outer frame
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
An energy exchange assembly comprising a plurality of membrane panels. Each of the plurality of membrane panels includes an outer frame defining a central opening; and a membrane sheet connected to the outer frame across the central opening. The membrane sheet is configured to transfer sensible energy and latent energy therethrough. A plurality of membrane spacers is separate from and positioned between the outer frames of two of the plurality of membrane panels. The membrane spacers includes a plurality of connecting brackets.