Woven Membrane Module Tubesheet Epoxy Wicking Control
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Solution Overview
Problem
Existing woven gas separation membrane modules face issues with voids in the tubesheet due to non-wettable warp threads preventing epoxy wicking, leading to weaker strength under high pressures, and using wettable threads results in epoxy wicking into the active region, compromising gas permeation.
Innovation Solution
A woven gas separation membrane module design where warp threads are spaced more densely in a sub-region adjacent to the active region to prevent epoxy wicking, using a single type of wettable warp yarn throughout, ensuring complete coverage and minimizing voids, thus maintaining gas permeability and mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If non-wettable or low-wettability synthetic thread is used in the selvage region to prevent wicking of potting composition, then wicking prevention is improved, but tubesheet strength deteriorates due to voids forming between fiber surface and tubesheet material
Solution Approach 1:
The patent applies local quality by using a dual-thread construction where the selvage region contains a non-wettable thread (such as polytetrafluoroethylene or silicone rubber) specifically positioned to prevent epoxy wicking, while the central active region uses a wettable thread that allows complete coverage by potting material. This localized differentiation of thread properties resolves the contradiction by preventing wicking only where needed without compromising tubesheet strength in the active region.
2Strength
If wettable thread is used instead of non-wettable thread, then tubesheet strength is improved through complete coverage, but epoxy wicking into the active region occurs compromising gas permeation
Solution Approach 1:
The patent implements local quality by differentiating thread properties across different regions of the fabric. The selvage region uses non-wettable thread to block epoxy wicking, while the central active region uses wettable thread to ensure complete potting material coverage and strength. This spatial differentiation of material properties simultaneously achieves both objectives without compromise.
3Object-generated harmful factors
If non-wettable thread is used to prevent wicking, then wicking prevention is improved, but manufacturing complexity increases due to the need for dual-thread weaving and precise positioning
Solution Approach 1:
The patent addresses manufacturing complexity by integrating the wicking prevention function directly into the fabric structure through localized non-wettable threads during the weaving process. This approach embeds the protective function within the material itself rather than requiring separate processing steps or complex assembly operations, thereby reducing overall manufacturing complexity while maintaining effective wicking prevention.
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 effectively prevents epoxy wicking into the active region, ensuring a strong, gas-tight tubesheet with minimal voids, maintaining high mechanical integrity and gas permeability, addressing the weaknesses of previous designs.
Implementation Method 1
hollow fibers that are semi-permeable to a gas mixture of interest
Implementation Method 2
warp threads being spaced more densely in the first sub-region than the second sub-region... prevents wicking of the potting composition up the bundle fibers
Data Source
AI summary
A gas separation membrane module is formed from a woven fabric of weft membrane hollow fibers and warp yarns. The membrane module includes an active hollow fiber region spanning the inner edges of the two tubesheets. The membrane module also includes two tubesheets formed by encapsulating membrane fiber on one or both ends. The tubesheet on the end includes a first sub-region adjacent the active fiber and a second sub-region extending from first sub-region to the outer face of the tubesheet. The spacing of the warp threads is relatively denser in the first sub-region than in the active region or the second sub-region.