Tricot Fabric Flow Path Material for High-Pressure Liquid Separation
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Solution Overview
Problem
Existing flow path materials for liquid separation apparatuses are prone to collapse under high pressure, leading to insufficient flow rates and increased maintenance costs, especially in reverse osmosis applications where long-term pressurization is required.
Innovation Solution
A tricot fabric made of thermoplastic core-sheath composite fibers with a high-melting-point core and low-melting-point sheath, knitted using a two-guide-reed machine, heat-pressed at 90°C and 4.0 MPa for 3 minutes, with specific density and thickness characteristics to minimize thickness change and prevent collapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fabric flow path material is rigidified by impregnating with epoxy resin or melamine resin to withstand high pressure, then the flow path material can resist deformation under pressure, but the resin elutes during sterilization or high-temperature treatment, causing contamination
Solution Approach 1:
The patent changes the material parameters by using thermoplastic synthetic fibers with specific melting points instead of resin-impregnated fabrics. The fibers are selected to maintain structural integrity at sterilization temperatures while providing sufficient pressure resistance through their inherent mechanical properties and knitting structure, eliminating the elution problem associated with resin-based rigidification
Solution Approach 2:
The patent employs a composite structure using two different thermoplastic synthetic fibers with complementary properties: one fiber provides heat resistance for sterilization durability, while the other provides structural support for pressure resistance. This composite fiber approach achieves both requirements without resin elution
2Strength
If thermoplastic synthetic fibers with different fineness are knitted using a three-guide-reed tricot knitting machine to achieve rigidification, then the flow path material can withstand pressure, but productivity decreases and manufacturing cost increases
Solution Approach 1:
The patent extracts the complex three-guide-reed knitting process and replaces it with a simpler two-guide-reed knitting process. By removing the unnecessary guide reed and simplifying the knitting mechanism, the patent maintains the functional requirements for pressure resistance while significantly improving manufacturing efficiency and reducing costs
Solution Approach 2:
The patent applies local quality differentiation by using fibers of different fineness in specific positions within the knitted fabric structure. Rather than requiring complex multi-guide-reed knitting, the patent strategically places thicker fibers in load-bearing areas and thinner fibers in other areas, achieving pressure resistance where needed while maintaining overall manufacturing simplicity
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 flow path material with high compression resistance, reducing the likelihood of collapse and flow rate reduction, enabling stable operation under high pressure for extended periods.
Implementation Method 1
the tricot fabric is rigidified by the thermoplastic core-sheath composite fibers being bonded to each other; and, when the tricot fabric is heat-pressed at 90° C. and 4.0 MPa for 3 minutes
Implementation Method 2
the tricot fabric is rigidified by the thermoplastic core-sheath composite fibers being bonded to each other
Implementation Method 3
thermoplastic core-sheath composite fibers each made of two kinds of polyester resins having different melting points or softening points
Data Source
AI summary
Provided is a flow path material for a liquid separation apparatus, which is less likely to collapse upon the application of a high pressure to the flow path material and causes a lower reduction of the flow rate. The flow path material for a liquid separation apparatus includes a tricot fabric containing thermoplastic core-sheath composite fibers each made of two kinds of polyester resins having different melting points or softening points. The flow path material for a liquid separation apparatus is configured such that: in the thermoplastic core-sheath composite fibers, a high-melting-point component is placed in the core, while a low-melting-point component is placed in the sheath; the tricot fabric is a tricot knitted fabric knitted with a two-guide-reed knitting machine using the thermoplastic core-sheath composite fibers as a front yarn and a back yarn and is rigidified by the thermoplastic core-sheath composite fibers being bonded to each other; the tricot fabric has a wale density of 45 to 70 yarns/inch (2.54 cm) and a course density of 40 to 70 yarns/inch (2.54 cm); and, when the tricot fabric is heat-pressed at 90° C. and 4.0 MPa for 3 minutes, the percentage of change in the thickness of the tricot fabric before and after pressing is 10% or less.