Spunbonded Nonwoven Support for Membrane Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current separation membrane supports lack high dimensional stability and peel strength, leading to instability in producing separation membranes at high yields and detachment issues during operation.
Innovation Solution
A spunbonded nonwoven fabric with specific properties, including boiling water shrinkage of -0.2 to 2.0%, water absorption time of 15 seconds or more, and Bekk smoothness of 5 to 35 seconds, is used as the separation membrane support, produced through thermocompression bonding with controlled cooling and surface temperatures to enhance mechanical strength and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a nonwoven fabric support is used to support separation membranes, then membrane formability is improved, but dimensional stability deteriorates causing deformation under heat or tension
Solution Approach 1:
The invention changes the physical-chemical parameters of the nonwoven fabric by controlling fiber orientation ratios (machine direction 30-70%, crosswise 30-70%), boiling water shrinkage (0.1-5.0% in width direction), and tensile strength ratios between directions. These parameter adjustments enable the support to maintain dimensional stability while preserving membrane formability.
Solution Approach 2:
The invention uses composite nonwoven fabric structures combining different fiber types and orientations to achieve both membrane formability and dimensional stability. The multi-component fiber composition and layered structure create a support that resists deformation while allowing membrane casting.
2Strength
If the support structure is made more robust to improve mechanical strength, then peel strength deteriorates causing membrane detachment
Solution Approach 1:
The invention applies local quality by creating different surface characteristics on the nonwoven fabric - the front surface (membrane formation side) is optimized for membrane adhesion with controlled roughness and porosity, while the overall structure provides mechanical strength. This localized optimization allows the membrane to firmly attach without the entire support structure needing to be uniformly robust.
3Ease of manufacture
If the nonwoven fabric is made more open to improve membrane casting, then mechanical strength deteriorates
Solution Approach 1:
The invention applies local quality by creating different surface characteristics on the nonwoven fabric - the front surface (membrane formation side) is optimized for membrane adhesion with controlled roughness and porosity, while the overall structure provides mechanical strength. This localized optimization allows the membrane to firmly attach without the entire support structure needing to be uniformly robust.
Solution Approach 2:
The invention transitions from considering only the openness of the nonwoven fabric to a three-dimensional structure with controlled fiber orientation in multiple directions. By adjusting fiber orientation ratios and creating a multi-layer structure, the support provides both casting capability and mechanical strength through spatial arrangement rather than just material density.
4Strength
If the support is designed for high pressure resistance, then processability deteriorates causing membrane bending or curling
Solution Approach 1:
The invention changes the physical parameters of the nonwoven fabric including fiber diameter distribution, fiber length, and compactness to achieve a balance between pressure resistance and processability. The controlled boiling water shrinkage and tensile strength ratios ensure the support can withstand high pressure while maintaining flatness during manufacturing processes.
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 solution provides a separation membrane support with excellent membrane formability, mechanical strength, and high peel strength, enabling stable production and preventing detachment during pressure fluctuations, thus improving the yield and durability of separation membranes.
Implementation Method 1
bonding a nonwoven fabric with thermocompression-bonding rolls for integrating a nonwoven fabric
Implementation Method 2
bringing the nonwoven fabric into contact with cooling rolls
Data Source
Figure 1~2
AI summary
Provided is a separation membrane support comprising a nonwoven fabric and having excellent membrane formability that achieves a high and stable yield when the separation membrane support supports various separation membranes such as microfiltration membranes, ultrafiltration membranes, nanofiltration membranes, and reverse osmosis membranes, having excellent processability when a fluid separation element is produced, and having excellent mechanical strength. Also provided are a separation membrane and a fluid separation element using the separation membrane support and having high membrane peel strength. The separation membrane support comprises a nonwoven fabric. The nonwoven fabric has a boiling water shrinkage of -0.2 to 2.0% in the length direction (longitudinal direction) after treatment in boiling water for 5 minutes. The separation membrane is prepared by forming a membrane having a separation function on a surface of the separation membrane support. The fluid separation element comprises the separation membrane as a constituent.