Protected Membrane Edge Structure for Thermal-Bonded Filter Modules
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Solution Overview
Problem
Existing filter modules face challenges in integrating polyolefin membranes into polyolefin components using thermal joining due to significant differences in melting point temperatures, leading to membrane retraction and failure in bonding.
Innovation Solution
A filter module design with edge structures embedded in anchoring elements, where the melting temperature differences between the edge structures and membrane are carefully controlled to prevent direct melt contact and temperature-induced damage during thermal joining, using materials like polyolefins and polyamides with specific melting temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polyolefin membranes are integrated into polyolefin components using thermal joining, then bonding between components is achieved, but the membrane retracts and fails to bond due to melting point temperature differences
Solution Approach 1:
The patent applies parameter changes by carefully selecting and controlling the melting temperature difference between the membrane and anchoring element within a specific range (-25 K to 60 K). This parameter optimization ensures that during thermal joining, the membrane melts sufficiently to bond with the anchoring element while maintaining its structural integrity and preventing retraction.
Solution Approach 2:
The patent implements local quality by applying edge structures with higher melting temperatures (at least 15 K higher than the membrane) specifically at the edge regions of the membrane. These edge structures remain stable during thermal joining, providing localized anchoring points that prevent membrane retraction while allowing the central membrane area to bond effectively.
2Reliability
If membranes with high porosity are used, then filtration performance is improved, but the membranes contain little material and retract during thermal joining
Solution Approach 1:
The patent employs composite materials by combining the high-porosity membrane material with edge structures made of materials having higher melting temperatures. This composite construction allows the membrane to maintain its filtration performance through high porosity while the edge structure provides the necessary mechanical strength and thermal stability to prevent retraction during bonding.
Solution Approach 2:
The patent applies segmentation by dividing the membrane into two functional zones: the central filtration area with high porosity for optimal filtration performance, and the edge region with reinforced structures for mechanical strength and retraction prevention. This segmentation allows each zone to optimize its specific function without compromising the other.
3Reliability
If halogen-containing materials are used for hydrophobicity, then water-repellent functionality is achieved, but environmental harm increases and recyclability decreases
Solution Approach 1:
The patent applies parameter changes by utilizing the inherent hydrophobicity parameter of polyolefin materials rather than applying halogen-containing coatings. Polyolefins naturally exhibit water-repellent properties due to their chemical structure, eliminating the need for harmful modifying substances while maintaining the required hydrophobic functionality.
Solution Approach 2:
The patent employs standard polyolefin materials that are inexpensive, widely available, and fully recyclable. These materials can be processed through conventional recycling streams without requiring special handling for halogen-containing substances, thereby reducing environmental harm and improving recyclability while maintaining functional performance.
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
Ensures effective bonding and retention of membrane structure, enhancing dimensional stability and resistance to heat, while avoiding environmentally harmful materials and facilitating recyclability.
Implementation Method 1
thermal joining, i.e. melting housing materials
Implementation Method 2
Attempts to thermally integrate polyolefin membranes into housing components made of polyolefins
Implementation Method 3
hydrophobic materials are used
Data Source
Figure 1~2C
Figure 3D~3J
Figure 4~6d
AI summary
The present invention relates to a filter module comprising a membrane (3), an edge structure (2), and an anchoring element (1), wherein the edge structure (2) is arranged over a surface of the membrane (3) in an edge region thereof and is embedded in the anchoring element (1), a difference between melting temperatures of the membrane (3) and the anchoring element (1) is from -25 K to 60 K, and a difference between melting temperatures of the edge structure (2) and the membrane (3) is 15 K or more. Moreover, the present invention relates to a method for producing the filter module as well as the use of the filter module for filtering a fluid medium.