Spiral-Wound Membrane Modules with Heat-Adhesive Yarn Bonding
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Solution Overview
Problem
Existing spiral wound-type separation membrane modules face high defect rates and long process times due to poor curing of epoxy resin and curing agent mixtures, and are not eco-friendly during disposal.
Innovation Solution
A spiral wound-type separation membrane module is manufactured using a heat-adhesive yarn wound around the filter assembly, which is melted and fixed to form an adhesion portion, replacing the conventional epoxy resin and curing agent process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy resin and curing agent mixture is sprayed during fiber winding, then adhesion is achieved, but curing time becomes excessively long and defect rate increases
Solution Approach 1:
The patent changes the fundamental parameter of the adhesion mechanism from chemical curing (epoxy resin + curing agent) to physical adhesion (heat-adhesive yarn melting). This parameter change transforms the curing process from a time-consuming chemical reaction to a rapid thermal bonding process, reducing curing time from hours to minutes while maintaining adhesion quality.
Solution Approach 2:
The patent replaces the chemical system (epoxy resin and curing agent mixture) with a thermal-mechanical system (heat-adhesive yarn that melts and bonds under heat). This substitution eliminates the need for chemical curing reactions and allows for much faster processing times while achieving comparable or superior adhesion.
2Reliability
If epoxy resin and curing agent mixture is used for lapping process, then adhesion is achieved, but defect rate increases due to scattering and poor curing
Solution Approach 1:
The patent replaces the chemical spraying system with a mechanical winding system that places heat-adhesive yarn precisely around the filter assembly. This mechanical approach eliminates the scattering and uneven distribution problems inherent in spray application, resulting in more consistent adhesion and lower defect rates.
Solution Approach 2:
The heat-adhesive yarn performs self-service by automatically providing uniform adhesion through its melting process. The yarn is wound in a controlled manner around the filter assembly, and when heated, it melts and bonds uniformly without requiring external curing agents or complex chemical reactions, thereby reducing defects.
3Reliability
If epoxy resin and curing agent mixture is used, then adhesion is achieved, but environmental friendliness deteriorates during disposal
Solution Approach 1:
The patent uses heat-adhesive yarn as a disposable, single-use component that can be easily replaced. The yarn is designed to melt and bond temporarily during the lapping process, and the entire assembly can be disposed of without environmental concerns, unlike epoxy resin which persists in the environment. This approach prioritizes ease of disposal and environmental friendliness over long-term durability.
Solution Approach 2:
The patent changes the material parameter from persistent chemical compounds (epoxy resin) to thermally-processable organic material (heat-adhesive yarn). This parameter change allows the adhesion material to be broken down more easily and disposed of in an environmentally friendly manner, eliminating the harmful effects associated with epoxy resin disposal.
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 method significantly reduces defect rates and process times while providing an eco-friendly disposal solution.
Implementation Method 1
a heat-adhesive polymer formed on the surface of the support fiber and having a lower melting point or softening point than the support fiber
Implementation Method 2
heat treating to melt part or all of the heat-adhesive yarn; and solidifying the molten heat-adhesive yarn to adhere and be fixed to the filter assembly
Data Source
AI summary
A spiral wound-type separation membrane module and a method for manufacturing the same are provided. The spiral wound-type separation membrane module according to an exemplary embodiment of the present invention is implemented by including an outlet pipe; a filter assembly wound in a spiral wound on the outlet pipe; and an adhesion portion in which part or all of a heat-adhesive yarn wound to surround the outer surface of the filter assembly in the longitudinal direction of the outlet pipe is melted and fixed to the filter assembly. According to the above, the spiral wound-type separation membrane module and the method for manufacturing the same can significantly reduce the defect rate and process time and simultaneously exhibit an eco-friendly effect during disposal after use.