Polymeric Hollow Fiber Membrane Sonication for Fouling Control
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Solution Overview
Problem
Existing methods for manufacturing polymeric membranes face challenges in independently controlling the incorporation of additives, leading to equipment buildup and inefficiencies in membrane formation, hollow fiber collapse during drying, and increased downtime for cleaning.
Innovation Solution
The use of sonication during various stages of the membrane formation process, including the spinning block, precipitation bath, washing bath, and drying chamber, to enhance mixing, reduce additive accumulation, and prevent equipment fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additives are added to spin mass to improve membrane properties, then membrane performance is enhanced, but equipment buildup and fouling occur
Solution Approach 1:
The patent applies ultrasonic vibration (sonication) to the spin mass solution before and during the membrane formation process. This mechanical vibration prevents additive accumulation on equipment surfaces by creating cavitation effects that disrupt material buildup, while simultaneously improving mixing homogeneity of the spin mass components.
2Manufacturing precision
If slow precipitation is used to improve membrane morphology, then membrane structure quality is enhanced, but production time increases
Solution Approach 1:
The patent employs periodic ultrasonic treatment during the precipitation process. The ultrasonic waves are applied in cycles that promote controlled phase separation and polymer aggregation, achieving desirable membrane morphology while reducing the overall precipitation time compared to conventional slow precipitation methods.
3Productivity
If continuous manufacturing is maintained to improve productivity, then output increases, but equipment cleaning downtime is required
Solution Approach 1:
The patent implements continuous ultrasonic treatment throughout the membrane formation process, preventing additive buildup on equipment surfaces during continuous operation. This eliminates the need for periodic shutdowns for cleaning, maintaining continuous productivity while preventing fouling accumulation.
4Stability of the object's composition
If ultrasonic treatment is applied to improve mixing, then component incorporation is enhanced, but energy consumption increases
Solution Approach 1:
The patent applies ultrasonic treatment at specific critical stages of the membrane formation process rather than continuously throughout. By targeting key moments when mixing and phase separation occur, the patent achieves sufficient homogeneity with reduced total energy input compared to continuous ultrasonic treatment.
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
Sonication improves membrane formation by reducing equipment buildup, minimizing downtime, and enhancing the properties of the membrane, such as reducing hollow fiber collapse and improving mixing of components.
Implementation Method 1
utilizing or applying sonication to one or more of the following steps or areas of the membrane formation process: the solution
Implementation Method 2
reduces or avoids fouling or buildup of the equipment used for polymeric membrane manufacturing
Data Source
AI summary
The present invention relates to a method to make polymeric membranes that are preferably useful in dialysis, wherein the method conducts at least one membrane-forming step and/or post-forming processing step with the use of sonication. Polymeric membrane, such as polymeric hollow fiber membrane, having improved one or properties are further described.