Multi-Layer Polymer Membrane for High-Speed Water Purification
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Solution Overview
Problem
Existing membrane distillation technologies are inefficient in producing large volumes of ultra-purified water quickly enough for industrial applications, particularly in semiconductor manufacturing, where the water must be highly purified and produced on-site to prevent contamination and ensure continuous operation.
Innovation Solution
A membrane distiller and distillation assembly featuring a multi-layer polymer membrane with a nonwoven first layer and a spunbonded second layer, which enhances the production of purified water while maintaining the required degree of purification, and includes a cooling chamber and polymer film for efficient cooling and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional membrane distillation techniques are used, then the production of ultra-purified water is achieved, but the production speed is too slow for industrial applications
Solution Approach 1:
The membrane is divided into multiple layers with distinct functions: a nonwoven first layer for purification and a spunbonded second layer for structural support and sealing. This segmentation allows each layer to optimize its specific function, improving overall productivity while maintaining purification quality
Solution Approach 2:
The invention uses a composite membrane structure combining nonwoven and spunbonded polymer layers. This composite material approach leverages the advantages of both materials - the nonwoven layer provides purification capability while the spunbonded layer provides structural integrity and sealing, resulting in higher production volumes at improved speeds
2Manufacturing precision
If the membrane pore size is reduced to increase purification, then the degree of purification is improved, but the production volume decreases
Solution Approach 1:
Different layers of the membrane have different pore sizes and properties tailored to their specific functions. The nonwoven first layer has smaller pores for high purification, while the spunbonded second layer has larger pores for structural support and fluid flow, allowing the system to achieve both high purification and high volume production
Solution Approach 2:
The composite membrane structure allows the first nonwoven layer to provide high purification with small pores while the second spunbonded layer maintains structural integrity and facilitates fluid flow, resolving the contradiction between purification degree and production volume
3Reliability
If the membrane is tightly sealed to prevent leaks, then the reliability is improved, but the membrane mounting becomes difficult and complex
Solution Approach 1:
The spunbonded second layer of the membrane is specifically designed with properties that facilitate sealing at its interface with the carrier/frame, while the nonwoven first layer maintains its purification function. This local quality differentiation allows reliable sealing without complicating the overall mounting process
Solution Approach 2:
The composite membrane structure with the spunbonded second layer provides inherent sealing capabilities that simplify the mounting process while ensuring reliable leakage prevention, eliminating the need for complex sealing mechanisms
4Manufacturing precision
If ultra-purified water is produced on-site to prevent contamination, then the purity is improved, but the water must be produced continuously which increases energy consumption
Solution Approach 1:
The membrane distiller is designed for continuous operation, maintaining a steady state of water purification without interruption. This continuous useful action ensures consistent purity while optimizing energy consumption by avoiding start-stop cycles and maintaining stable operating conditions
Solution Approach 2:
The membrane distiller system is designed to be self-regulating and maintain purification quality automatically during continuous operation, reducing the need for external intervention and optimizing energy usage by leveraging the inherent properties of the membrane system
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 solution enables the efficient and continuous production of large volumes of ultra-purified water with enhanced purification capabilities, reducing the need for frequent water changes and minimizing contamination risks, thus meeting the demands of semiconductor manufacturing.
Implementation Method 1
the membrane has a pore size equal to or less than 1000 nanometres
Implementation Method 2
a membrane distiller configured for producing purified water, the membrane distiller having an evaporation chamber and a condensation chamber
Implementation Method 3
a membrane distiller configured for producing purified water, the membrane distiller having an evaporation chamber and a condensation chamber
Data Source
AI summary
A membrane distillation assembly for providing purified water, and to a membrane distiller including an evaporation chamber, a condensation chamber, and a membrane separating the evaporation chamber and the condensation chamber from each other. The membrane has a pore size equal to or less than 1000 nanometres. The membrane distiller wherein the membrane is a multi-layer polymer membrane including a nonwoven first layer having a pore size equal to or less than 1000 nanometres and a spunbonded second layer that is laminated to the first layer. The second layer is facing the condensation chamber.