Seamless Membrane Bags for MBR Filtration

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Solution Overview

Problem

Existing membrane bioreactor systems face issues with poor adhesion of membranes to their supports, leading to detachment, operational problems due to insufficient back-flushing pressure, and high production costs associated with sealing requirements.

Innovation Solution

A seamless membrane bag design featuring a spacer fabric with monofilament threads forming loops, impregnated with membrane substance to create an integrated permeate channel without external seams, allowing for efficient permeate collection and withstanding high backwash pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If membranes are bonded to support plates using conventional methods, then structural support is provided, but adhesion is poor leading to detachment

Engineering Contradiction:

Improvemembrane adhesion to supportVSAvoidmembrane detachment resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The support plate and membrane are merged into a single integrated structure by forming the membrane directly on the support plate surface. The membrane substance is applied to cover the support plate, creating a bonded interface that eliminates detachment issues while maintaining structural support functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A composite structure is created by combining the support plate material with the membrane substance. The membrane substance forms a layered composite on the support plate, where the two materials work together to provide both mechanical support and filtration functionality with strong interfacial adhesion.

Inventive Principle:

Principle #40Composite materials

2Productivity

If external sealing is used to enclose permeate collection channels, then permeate can be collected, but sealing requirements increase production costs

Engineering Contradiction:

Improvepermeate collection efficiencyVSAvoidproduction cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The permeate collection channel is merged with the membrane structure itself. The channel is formed as an integral part of the membrane-substrate composite, eliminating the need for separate external sealing components. This integration maintains permeate collection functionality while removing complex sealing requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The membrane substance itself forms a flexible enclosing structure that defines the permeate collection channel. Instead of rigid external seals, the flexible membrane substance creates the channel boundaries, allowing permeate collection without additional sealing components.

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of operation

If conventional membrane filtration is used, then filtration is achieved, but back-flushing pressure is insufficient leading to operational problems

Engineering Contradiction:

Improvefiltration functionalityVSAvoidback-flushing pressure resistance

Core Design Contradiction:

Ease of operationVSStress or pressure

Solution Approach 1:

The composite structure of the support plate and membrane substance creates a mechanically robust filtration system. The support plate provides structural strength to withstand high back-flushing pressures, while the membrane substance maintains filtration functionality. This composite construction enables both effective filtration and resistance to operational stresses.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If seamless membrane design is implemented, then external sealing is eliminated, but manufacturing complexity increases

Engineering Contradiction:

Improvesealing requirementVSAvoidmembrane structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The support plate and membrane are combined into a single manufactured unit. By forming the membrane directly on the support plate in one process, the invention eliminates the need for separate sealing operations and assembly steps, actually reducing manufacturing complexity despite the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

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 seamless membrane bags provide enhanced durability, increased filtration efficiency, and reduced production costs by eliminating the need for external sealing, while maintaining high permeability and resistance to backflush pressures.

Implementation Method 1

the first and second parts of the fabric are impregnated with membrane substance to form two membranes having an integrated permeate channel between the innermost surfaces

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

the monofilament spacer thread preferably forming loops through the first and second parts of the spacer fabric

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS8061531B2Membrane bags with seamless membrane substance, uses thereof and filtration units therewith

Publication Date: 2011.11.22 BLUE FOOT MEMBRANES NV

AI summary

A membrane bag comprising a volume for permeate collection, wherein the volume is completely enclosed in seamless membrane substance; a filtration unit comprising at least one above-described seamless membrane bag; the use of at least one above-described seamless membrane bag in a membrane bioreactor; the use of at least one above-described seamless membrane bag in water filtration or waste water purification; and the use of at least one above-described seamless membrane bag for the filtration or separation of a mixture of fluids, vapors and particles.