Perforated Plate Design for Gas Separation Membrane Modules

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Solution Overview

Problem

Conventional gas separation membrane modules with perforated plates are prone to deformation, which can lead to breakage of the tube sheet, especially under high-pressure conditions, as the through holes are often formed in thinner portions not in contact with the lid, compromising the structural integrity.

Innovation Solution

The design incorporates a perforated plate with a flat portion in contact with the lid and a channel-forming recess portion, where through holes extend over both areas, creating a stable gas channel and distributing pressure evenly to prevent deformation, and optionally features elongated holes and recesses for enhanced structural support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If through holes are formed in thinner portions of the perforated plate not in contact with the lid, then gas channels can be formed, but the perforated plate deforms under pressure causing tube sheet breakage

Engineering Contradiction:

Improvegas channel formationVSAvoidperforated plate deformation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention applies local quality by creating a recess portion in the perforated plate at the location where the through hole is formed. This recess portion locally increases the thickness of the perforated plate only where needed to prevent deformation, while maintaining the overall thin design for gas channel formation. The recess portion is positioned to receive pressure from the tube sheet, providing structural support exactly where the through hole creates potential weakness.

Inventive Principle:

Principle #3Local quality

2Device complexity

If the perforated plate is made thinner to facilitate through hole formation, then gas channels are easier to create, but the structural strength decreases leading to deformation

Engineering Contradiction:

Improveperforated plate structureVSAvoidperforated plate strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The invention applies the nesting principle by creating a recess portion that is nested within the perforated plate structure. The recess portion is formed by removing material from one surface of the perforated plate, creating a stepped or nested configuration. This nested structure allows the perforated plate to maintain its thin overall profile while having a localized thicker region (the recess) that provides the necessary strength to prevent deformation under pressure.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Productivity

If the perforated plate deforms, then gas channels may form more easily, but the tube sheet breaks and module integrity is compromised

Engineering Contradiction:

Improvegas separation efficiencyVSAvoidtube sheet breakage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention applies beforehand cushioning by pre-forming a recess portion in the perforated plate during manufacturing, before the module is assembled and pressurized. This recess portion acts as a pre-prepared structural reinforcement that cushions and absorbs the pressure stress that would otherwise cause deformation. By preparing this protective feature in advance, the invention prevents tube sheet breakage before it can occur during operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 configuration effectively prevents deformation of the tube sheet, reducing the risk of breakage and maintaining module integrity even under high-pressure conditions, while allowing efficient gas separation.

Implementation Method 1

a hollow fiber element having a hollow fiber bundle consisting of a number of hollow fiber membranes with permselectivity

Methodology Applied

Scientific EffectPermselectivity: Semipermeable Membrane

Implementation Method 2

the perforated plate has (a) a flat portion, on a surface closer to the lid, the flat portion configured to generally be in contact with the lid member when mounted

Methodology Applied

Scientific EffectPressure distribution: Pascal's Law

Implementation Method 3

a perforated plate having a plurality of through holes for forming gas channels formed therein

Methodology Applied

Scientific EffectGas flow through channels: Pressure Gradient

Data Source

PatentUS9199191B2Gas separation membrane module and method of replacing a hollow fiber element

Publication Date: 2015.12.01 UBE CORPORATION

AI summary

A gas separation membrane module, comprising: a hollow fiber element having a hollow fiber bundle consisting of a number of hollow fiber membranes and a tube sheet provided at an end of the hollow fiber bundle for binding the hollow fiber membranes; a vessel having an opening through which the hollow fiber element is inserted or removed; a lid member having a gas outlet formed therein and attached to cover the opening of the vessel; and a perforated plate having a plurality of through holes for forming gas channels formed therein, the perforated plate being mounted between the tube sheet and the lid member, the gas separation membrane module performing gas separation by supplying mixed gas to the hollow fiber membranes.