Membrane Support with Integrated Air Channels

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Solution Overview

Problem

Existing membrane cartridges in filtration systems face challenges in achieving uniform air bubbling and maximizing membrane surface area per unit volume, leading to inefficiencies and increased operational costs, particularly in large bioreactors and filtration apparatuses.

Innovation Solution

A planar membrane cartridge design featuring a support with integrated fluid compartments and channels, where the semi-permeable membrane covers only the central area portion, allowing for separate compartments for air bubbling and permeate extraction, enabling more compact and cost-effective systems with improved performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If air bubbling is applied to create upward flow of waste water along membranes, then filtration performance is improved, but aeration occupies significant volume that cannot be used for filtration

Engineering Contradiction:

Improvefiltration performanceVSAvoidvolume available for filtration

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The support structure integrates both the membrane support function and the air distribution function into a single component. The support includes integrated air channels and embossments that directly deliver air bubbles to the membrane surface, eliminating the need for separate external aerators and maximizing the volume available for filtration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The air channels and embossments are nested within the support structure itself, with the support forming a multi-functional assembly where the membrane layer is attached to the embossed portions and the support contains integrated air distribution pathways, allowing air bubbling functionality to be embedded within the filtration cartridge.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If membrane surface area is increased per unit volume, then filtration efficiency is improved, but system complexity increases

Engineering Contradiction:

Improvemembrane surface area per unit volumeVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The support is divided into distinct functional zones including a central area portion with embossments for membrane attachment, edge area portions for sealing and structural support, and integrated air channels. This segmentation allows for optimized membrane surface area while maintaining manageable structural complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structure utilizes three-dimensional embossments and layered construction to create vertical air channels and fluid compartments, transitioning from two-dimensional membrane surfaces to three-dimensional air distribution pathways, thereby increasing membrane surface area utilization without proportionally increasing system complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If uniform air bubbling is ensured along all membrane surfaces, then filtration uniformity is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveair bubbling uniformityVSAvoidmanufacturing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The support structure incorporates localized embossments and air channels positioned at specific locations to ensure uniform air distribution. The edge area portions are designed with specific sealing features and air channel configurations that are optimized for their local function, allowing for manufacturable variations while achieving overall uniform performance.

Inventive Principle:

Principle #3Local quality

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

The design enhances weight, cost, and manufacturing efficiency while providing uniform air bubbling and increased membrane surface area, leading to improved operational performance and reduced operational costs in filtration systems.

Implementation Method 1

a semi-permeable membrane layer (11) attached to the first layer (16) in the central area portion (128)

Methodology Applied

Scientific EffectSemipermeable membrane filtration: Semipermeable Membrane

Implementation Method 2

The first layer (16) is porous in the central area portion (128)

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS11577203B2Membrane support made with preformed sheets

Publication Date: 2023.02.14 VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK NV (VITO)

AI summary

A planar membrane cartridge includes a support and a semi-permeable membrane layer. The support includes a first layer attached to a second layer and defining a front face and a back face of the support. At least one of the first layer and the second layer form a first embossment and a second embossment. Respective back faces of the first layer and the second layer are attached to each other along edges of the first embossment and of the second embossment, such that the first embossment defines a fluid compartment between the first layer and the second layer and the second embossment defines an internal channel between the first layer and the second layer which is isolated from the fluid compartment. An area of the first layer corresponding to the first embossment is covered by the semi-permeable membrane layer.