Spiral Wound Filtration Module with Wedge Support for Void Prevention
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Solution Overview
Problem
Spiral wound filtration modules suffer from void formation during assembly, leading to bypass flow, adhesive irregularity, and performance variability, along with increased risk of integrity failures due to manual adhesive application.
Innovation Solution
Incorporation of a wedge-shaped support at the leading edge of membrane packets to prevent void formation and adhesive migration, coupled with a method using vacuum to distribute adhesive uniformly, and impermeable feed screen borders to maintain consistent feed and permeate channel geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spiral winding of membrane packet is performed, then filtration module assembly is completed, but wedge-shaped void forms in front of leading edge causing bypass flow
Solution Approach 1:
A compressible support element is introduced as an intermediary component between the membrane packet and the winding path. This support element fills the wedge-shaped void that forms during spiral winding, preventing bypass flow while allowing the membrane packet to be properly wound. The support element acts as a mediator that eliminates the harmful void without interfering with the filtration function.
2Strength
If adhesive is manually introduced to bind layers, then layers are secured, but irregular adhesive border causes variability in membrane area and integrity failures
Solution Approach 1:
The manual adhesive application process is replaced with an automated adhesive dispensing system. This mechanical substitution eliminates human error and ensures consistent adhesive application along the winding path. The automated system provides precise control over adhesive quantity and positioning, resulting in uniform membrane area and reduced integrity failures while maintaining strong layer binding.
3Device complexity
If membrane packet is wound around core, then spiral structure is formed, but void space requires adhesive filling increasing adhesive usage
Solution Approach 1:
The compressible support element serves as a mediator that defines the internal geometry of the spiral structure. By providing a rigid framework during winding, it eliminates void spaces that would otherwise require adhesive filling. This reduces adhesive quantity while maintaining the structural integrity of the spiral configuration.
Solution Approach 2:
The introduction of the support element changes the physical parameters of the winding assembly by providing structural rigidity and defining the internal volume. This parameter change eliminates the need for excessive adhesive to fill voids, as the support element itself occupies and defines the necessary spatial parameters.
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
Enhances performance consistency, reduces pressure drop variability, and minimizes adhesive usage, while preventing adhesive intrusion into feed channels, thereby improving the reliability and efficiency of spiral wound filtration modules.
Implementation Method 1
applying a vacuum to the permeate core, tube or mandrel, whereby the vacuum drives the adhesive into the permeate channels and around the outer perimeter of the core
Data Source
AI summary
A spiral wound membrane module, comprising a perforated core having an axially extending internal bore; at least one membrane packet comprising a folded membrane sheet defining a first outer face, a first inner face, a second outer face and a second inner face, the fold of the folded membrane sheet being a leading end of the membrane packet; a feed sheet positioned between the first and second inner faces so as to be sandwiched by the folded membrane sheet; a first permeate screen adjacent the first outer face of the membrane sheet defining a first permeate channel; a second permeate screen adjacent the second outer face of the membrane sheet defining a second permeate channel; and a fluid impermeable support coupled to the leading edge of the membrane packet. Also disclosed is a method of manufacturing the spiral wound membrane module.