Thermoplastic Resin Membrane Element Bonding
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Solution Overview
Problem
Existing membrane element manufacturing methods, such as ultrasonic fusion bonding, face challenges with low fixing strength, ease of membrane peeling, and high costs associated with large-scale production, where the replacement of filtration membranes is difficult and costly due to deformation of the thermoplastic resin plate, leading to increased waste and facility costs.
Innovation Solution
A method where a microporous filtration membrane made of synthetic resin fibers is joined to a thermoplastic resin plate using a hot plate with controlled temperature, ensuring the nonwoven fabric substrate is not fused, allowing for secure attachment and easy replacement of the filtration membrane, thus maintaining the strength of both components and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic fusion bonding is used to join the filtration membrane to the resin plate, then the membrane can be fixed to the plate, but the fixing strength is low and the membrane is easy to peel off
Solution Approach 1:
The patent changes the joining method from ultrasonic fusion bonding to hot plate heating, controlling the temperature parameter to be below the melting point of the resin plate. This parameter change allows the membrane to be pressed onto the plate without fusing the resin, creating a more reliable mechanical attachment that prevents peeling while maintaining fixing strength.
Solution Approach 2:
The patent replaces the ultrasonic mechanical vibration system with a thermal field system (hot plate). Instead of using high-frequency mechanical vibrations to fuse the membrane, the invention uses controlled heating to soften the resin plate slightly, allowing the membrane to be pressed onto it. This substitution creates a more durable connection that resists peeling.
2Ease of manufacture
If the resin plate is deformed during fusion bonding to join the membrane, then the membrane can be attached, but the membrane element cannot be reused and replacement costs increase
Solution Approach 1:
The patent controls the temperature parameter during joining to be below the melting point of the resin plate, preventing permanent deformation. This allows the plate to maintain its original shape and structure after membrane attachment, enabling the same plate to be reused with multiple membranes without degradation or the need for costly replacement.
3Strength
If adhesive is used to fix the membrane to the resin plate, then the membrane can be attached, but the working environment is deteriorated by solvent and drying and curing takes time
Solution Approach 1:
The patent replaces the chemical adhesive system with a physical/thermal system. Instead of using adhesives that require solvent evaporation and chemical curing, the invention uses controlled heating to temporarily soften the resin plate, allowing the membrane to be pressed onto it. This eliminates the time-consuming drying and curing processes while maintaining strong attachment.
Solution Approach 2:
The patent extracts and eliminates the adhesive component from the joining process. By using hot plate heating to directly attach the membrane to the resin plate, the invention removes the need for adhesive materials, their solvents, and the associated environmental and temporal issues.
4Strength
If adhesive is used to fix the membrane to the resin plate, then the membrane can be attached, but the fixing strength varies depending on adhesive strength and durability
Solution Approach 1:
The patent replaces the variable-performance adhesive system with a consistent physical process. By using hot plate heating to control the resin plate's softening, the invention creates a repeatable and reliable attachment process that does not depend on adhesive quality, batch variations, or environmental factors, ensuring consistent fixing strength.
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 approach enhances the cost-effectiveness and durability of the membrane element by maintaining the strength of the nonwoven fabric, allowing for uniform filtration performance, easy replacement of filtration membranes, and simplifying the manufacturing process, particularly for large-sized membrane elements.
Implementation Method 1
joining the microporous filtration membrane to the flat surface of a peripheral part of a thermoplastic resin plate by applying pressure to the thermoplastic resin plate via the microporous filtration membrane by a hot plate whose temperature is controlled
Implementation Method 2
when the temperature in fusion bonding this substrate to a plate for filtration made of such as an ABS resin by ultrasonic wave is lower than 140° C., the plate is fused and the fused resin is impregnated into the nonwoven fabric
Data Source
AI summary
A membrane element in which, after membrane breakage or deterioration, the filtration plate made of a thermoplastic resin can be reused to replace the membrane with a fresh one. The membrane element comprises a filtration plate made of a thermoplastic resin and, bonded to a peripheral smooth surface thereof, a microporous filter membrane which has fine pores formed therein and employs a nonwoven fabric comprising synthetic resin fibers as a support. A hot plate having a shape corresponding to the peripheral shape of the resinous filtration plate is brought into contact with a peripheral smooth surface of the plate so as to form a recessed part in the surface. The temperature of the hot plate is regulated so as to be not higher than the melting point of the nonwoven fabric serving as the support and not lower than the Vicat softening temperature of the filtration plate made of a thermoplastic resin. The thermoplastic-resin filtration plate is pressed with this hot plate through the microporous filter membrane to bond it to the membrane.