CN110248802A - 螺旋卷绕元件的干扰图案 - Google Patents

螺旋卷绕元件的干扰图案 Download PDF

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CN110248802A
CN110248802A CN201780071166.4A CN201780071166A CN110248802A CN 110248802 A CN110248802 A CN 110248802A CN 201780071166 A CN201780071166 A CN 201780071166A CN 110248802 A CN110248802 A CN 110248802A
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hinge
protrusions
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active surface
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凯文·罗德里克
罗德尼·赫林顿
肯德尔·魏因加特
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Abstract

本发明的实施例提供了在整个折叠膜片或其多个部分的两个相对表面上、结合沉积在同一膜片的多个部分上的特征进行间隔元件沉积，以产生以其他方式无法实现的间隔几何形状。

Description

螺旋卷绕元件的干扰图案
技术领域
本主题发明涉及一种可用于流体组分分离的渗透膜系统，该渗透膜系统包括螺旋卷绕膜渗透膜元件。
背景技术
螺旋卷绕膜过滤元件由层压结构构成，该层压结构包括密封到多孔渗透间隔件上或围绕该多孔渗透间隔件的膜片，该多孔渗透间隔件产生了用于将穿过该膜到中心管的流体移除的路径，同时这个层压结构被螺旋地缠绕在该中心管周围并且用多孔供给间隔件与自身隔开，从而允许流体轴向流动通过该元件。在这个供给间隔件必须保持敞开以及在该层压结构之间均匀的轴向流动的同时，该供给间隔件还是在轴向流动通道内的流动限制和压降的来源并且还呈现出流动限制区域并且与膜发生接触，这由于生物滋长、结垢、和颗粒捕获而显著易于膜污染。
对螺旋卷绕元件的设计的改进已经由巴里耶(Barger)等人和布雷福德(Bradford)等人披露，这些改进用沉积或直接压印到膜的外侧或活性表面上的岛状物或突出物来代替供给间隔件。这种构型的有利之处在于它保持了用于轴向流过该元件的间距，同时使流动通道内的阻碍最小化。该构型消除了作为分开部件的多孔供给间隔件，从而简化了元件的制造。标题为“改进的螺旋卷绕元件构造(Improved Spiral Wound ElementConstruction)”的专利公开号US 2016-0008763-A1教导了在膜片的活性表面的背侧或者直接在渗透物间隔件的表面上应用印刷图案。
以下参考文献(其中的每一个都通过援引并入本文)可以有助于理解本发明：US3962096；US 4476022；US 4756835；US 4834881；US 4855058；US 4902417；US 4861487；US6632357；以及美国申请2016-0008763-A1。
发明内容
本发明的实施例提供了一种用于在螺旋卷绕过滤元件中使用的膜，该膜包括第一页片和第二页片，其中每个页片具有活性表面，该活性表面具有布置在该表面上的多个突起，这些突起被成形并布置在该表面上使得当该第一页片的活性表面邻近该第二页片的活性表面放置时，这些突起彼此接触，该第一页片上的突起通过该第二页片上的突起与该第二页片的活性表面分离；其中，该第一页片和该第二页片被放置为使得活性表面彼此面对并且通过突起而分离。这两个页片可以是由合适材料制成的分离的片，或者可以通过折叠单个片来提供，其中该折痕的每一侧提供一个页片。注意，用于在螺旋卷绕过滤元件中使用的膜固有地具有两个边缘，即供给边缘和拒收边缘，这两个边缘对应于膜的这些边缘，这些边缘将分别遇到供给流体流和逐出废流体流。这种膜还固有地具有一定宽度，该宽度对应于该供给边缘和该拒收边缘之间的材料的尺寸。
在一些实施例中，突起包括多个线形突起，其中这些线形突起彼此平行布置，并且在相应页片的表面上的所有平面方向上彼此分离；并且其中，这些线形突起以与相应页片的供给边缘成除了90度之外的角度布置在表面上，使得该第一页片上的线形突起在它们的交点处接触该第二页片上的线形突起。线形突起可以延伸穿过页片的整个宽度，或者可以延伸穿过的宽度小于整个宽度。在一些实施例中，角度在40度与85度之间、或者在100度与135度之间。在一些实施例中，突起从每个页片的表面突出至少0.065mm、但不超过0.4mm。在一些实施例中，突起包括多个弯曲特征，这些弯曲特征被构造成使得当该膜螺旋卷绕时，第一页片上的弯曲特征将以除了0度以外的角度与第二页片上的弯曲特征相交。在一些实施例中，线形突起在轴向尺寸上至少为20mm长(螺旋卷绕时平行于中心管的轴线测量的长度分量)，并且线段之间的间距小于线段的长度。
在一些实施例中，突起布置在第一页片的第一区域中，并且布置在第二页片的第一区域中，该实施例进一步包括多个流动突起，这些流动突起布置在(a)第一页片的活性表面上而不是第一页片的第一区域中，布置在(b)第二页片的活性表面上而不是第二页片的第一区域中，或者布置在(c)两者，其中流动突起具有的高度约等于第一页片的第一区域中突起的高度和第二页片的第一区域中突起的高度之和，并且其中当元件螺旋卷绕时，一个页片上的流动突起不接触另一页片上的那些流动突起。
在一些实施例中，线形突起布置在相应页片的最接近供给边缘和拒收边缘的区域中，并且该实施例进一步包括多个流动突起，这些流动突起布置在(a)除了由线形突起占据的那些区域之外的区域中的第一页片的活性表面上，布置在(b)除了由线形突起占据的那些区域之外的区域中的第二页片的活性表面上，或者布置在(c)两者，其中流动突起具有的高度约等于第一页片上的线形突起的高度和第二页片上的线形突起的高度之和；并且其中，当元件螺旋卷绕时，一个页片上的流动突起不接触另一页片上的那些流动突起。
本发明还提供了一种制造膜的方法，该方法包括提供第一页片和第二页片，该第一页片和第二页片各自具有活性表面；将多个突起放置在每个页片的活性表面上，这些突起被成形并布置在该表面上使得当该第一页片的活性表面邻近该第二页片的活性表面放置时，这些突起彼此接触，同时该第一页片上的突起通过第二页片上的突起而与该第二页片的活性表面分离；将该第一页片的活性表面邻近该第二页片的活性表面、由这些突起分离地放置。提供第一页片和第二页片可以包括提供两个分离的片，或者可以包括提供片，该片通过折线分成第一页片和第二页片。
本发明还提供了一种过滤元件，该过滤元件如本文所述的那些过滤元件、螺旋卷绕在中心管上。本发明还提供了一种流体处理系统，该流体处理系统包括多个过滤元件(如本文所述的那些过滤元件)。本发明还提供了一种处理流体的方法，该方法包括使流体流经过滤元件(如本文所述的那些过滤元件)。
一些实施例提供了一种用于在螺旋卷绕过滤元件中使用的膜，该膜包括具有活性表面的片，该片被折叠为在折叠片内侧具有活性表面，其中活性表面具有布置在其上的多个突起，这些突起被成形并布置在表面上，使得这些突起彼此接触并保持折叠片中的面对的活性表面分开。在一些实施例中，突起包括多个线形突起，这些线形突起以与膜的供给边缘成除了90度之外的角度布置在活性表面上。在一些实施例中，该角度在40度与85度之间，或者在100度与135度之间。在一些实施例中，这些突起从片的表面突出至少0.065mm、但不超过0.4mm。
附图说明
图1是在单一折叠的膜页片的相对面上的实线的相对图案的图示。
图2是在单一折叠的膜页片的相对面上的分段线的相对图案的图示。
图3是膜页片的图示，其中半高边缘图案沿着页片的入口边缘和出口边缘的全长沉积，并且全高特征沉积在膜页片的二分之一膜页片上。
图4是膜供给间隔件的表示，这些膜供给间隔件在膜元件的供给端上具有弯曲的引入特征并且是在膜元件被卷起之后被修整。
图5是膜供给间隔件的表示，这些膜供给间隔件在膜元件的供给端上具有弯曲的引入特征，并且具有弯曲的防伸缩装置特征以帮助避免高固体含量流体(high solidsfluids)引起的元件端部堵塞。
具体实施方式
与供给间隔网相比，将特征压花或沉积到膜片的表面上、或者压花或沉积到螺旋卷绕元件的渗透物载体片上、或者压花或沉积在渗透物载体片之中以在相邻膜片之间提供间距可以提供若干优点，这些优点包括更多开放的流动通道、更低的压降、减少的结垢、以及产生比使用网的实践的更薄的供给空间的能力。由Barger等人、Bradford等人并且在PCT/US 2014/018813中已经披露了多种不同的构型。本发明的实施例提供了印刷或以其他方式沉积的表面特征的用途，这些表面特征选择性地彼此接触以在相邻膜片之间提供间隔，从而产生了通过孤立岛状物沉积所不能实现的独特的接触和流动模式。由此产生的图案还可以包含彼此没有接触以在螺旋卷绕元件内提供附加的间隔和流动方向的其他沉积特征。此外，印刷的或以其他方式沉积的特征的可变高度可以用于在螺旋卷绕元件的不同区域上产生不同的间隔件几何形状。
印刷、压花或以其他方式沉积特征以在螺旋卷绕元件中提供间隔的先前披露内容典型地包括将特征沉积在每个折叠膜页片的二分之一膜页片上以提供间隔，而同时消除在页片折叠时这些特征彼此接触或堆叠的可能性。因为页片部分彼此之间以及页片部分与元件的其余组件之间的变化的半径，当螺旋卷绕元件被卷起时，接触和几何形状的考虑变得更加复杂。然而，在某些情况下，使间隔元件(这些间隔元件被设计成在折叠时彼此接触)沉积在膜表面的整个表面或部分表面上是有益的。沉积图案或特征可以被构造成使得当片被折叠和卷起时，图案在任何点处都没有可能嵌套在相对的图案中，并且确保特征对特征的接触而不是特征对膜的接触。
在图1所示的示例实施例中，一系列连续成角度的平行线10沉积在膜表面上、从对应于卷起的元件的入口流的边缘延伸到对应于出口流的边缘。在这个示例中，印刷线可以具有在0.065mm与0.80mm之间宽度以及从0.065mm至0.40mm的高度。相邻元件之间的间距应是足够近的，以防止在膜卷起期间在平行线之间的膜片由于所使用的用来在膜片、相邻渗透物载体和下一个膜片之间形成包络的粘合剂的粘度而引起的溃陷。对于目前常用的材料，这个间隔从一条线到下一条线可以不超过3mm、并且更优选为2.5mm。从入口流边缘14开始的在0°与90°之间的或者在90°与180°之间的任何角度都可以用来确保折叠页片上的特征到特征的接触，但是在从45°至80°或者从100°至135°范围内的角度更适合于保持通过该元件的可接受的流量和压降。当折叠时，沉积的图案10将以补角接触相对的图案12，使得沉积的图案将重复地彼此交叉和支撑，而不会使来自相对侧的图案直接接触膜薄膜。这些线可以是如图所示的直线，也可以是弯曲的、正弦形的或其他形状的，只要它们不包含图案接近90°的延伸段(例如<10mm)。可以为特定的性能特性选择不是直线的图案，例如，以用于改善混合或延长或缩短穿过膜表面的流动路径。
在图2中所示的另一示例实施例中，可以使用线段20代替连续的线，以产生在折叠时将接触自身22的图案。在这个示例中，印刷图案可以具有在0.065mm与0.80mm之间的宽度以及从0.065mm至0.40mm的宽度。相邻元件之间的间距应是足够近的，以防止在膜卷起期间在平行线之间的膜片由于所使用的用来在膜片、相邻渗透物载体和下一个膜片之间形成包络的粘合剂的粘度而引起的溃陷。对于目前常用的材料，这个间隔从一条线到下一条线可以不超过3mm、并且更优选为2.5mm。从入口流边缘24开始的在0°与90°之间的或者在90°与180°之间的任何角度都可以用来确保折叠页片上的特征到特征的接触，但是在从45°至80°或者从100°至135°范围内的角度更适合于保持通过该元件的可接受的流量和压降。螺旋卷绕元件卷起，即使以自动化方式进行，也仍然是不精确的。由于在组装中所使用的多种不同的片材和胶的移动，给定的元件内的典型折叠页片能够向元件的中心管轴向地移动多达+/-10mm。因此，在轴向尺寸方面通常需要超过20mm的最小特征长度，以确保折叠页片中相邻特征之间的接触。相邻线段之间在轴向尺寸上的间隙短于轴向尺寸上的特征长度，以避免折叠时特征嵌套的任何可能性。在此实施例中，线段也可以是直的、弯曲的、正弦形的或以其他方式重复变化的。
通过在折叠时特征相遇以便彼此进行支撑之处使全页片长度与未被设计成在折叠之后与相邻特征干扰的特征沉积区域相结合，也可以增强在元件入口和出口边缘处维持开口间距，同时最小化流动通道内的流动限制。这允许图案(这些图案未被设计成在折叠之后与相邻特征干扰)包括不限于线或线段的各种形状，诸如圆形或多边形柱、弯曲线段或以期望方式改变流动的其他形状。在图3所示的示例中，沿着入口32和出口34边缘的印刷干扰图案30可以具有在0.065mm与0.80mm之间的宽度和从0.065mm至0.40mm的高度，并且从膜页片的入口和出口边缘轴向延伸从40mm至80mm。与入口和出口流动边缘成0°与90°之间或在90°与180°之间的任何角度可以用来确保折叠页片上的特征到特征的接触，但是从45°至80°或从100°至135°范围内的角度更适合于保持通过元件的可接受的流量和压降。另一图案沉积在膜页片的二分之一膜页片上的中心部分30中，并且可以是边缘上的特征的两倍高，使得当页片沿着其中心线38折叠时，边缘和中心区域上的间距是均匀的。一般而言，沉积在边缘处的图案更密集地间隔开，以支撑用于将页片粘合在一起的胶线，而中心图案更稀疏地间隔开，以允许通过元件的这一部分的较少限制的流动。
在特定的示例性实施例中，实线段30的图案(0.6mm宽和93mm长)被沉积为从入口32边缘和出口34边缘以相对于膜片的边缘成45°的角度延伸，使得它以所需最终供给空间高度的二分之一高度向内延伸66mm到页片上，在这种情况下，对于折叠之后的0.4mm的总供给间隔来说延伸0.2mm。另一图案(直径为1.2mm、彼此间隔6.5mm的圆形柱36的正方形阵列)然后沉积在两个0.2mm的图案之间的中心区域上，达0.4mm的高度。此图案仅沿着整个页片的二分一长度沉积，使得当页片在中心线38处被对折时，边缘图案相互接触以在边缘处产生0.4mm的供给空间，而中心图案在页片的中间产生0.4mm的间隔。
在图4所示的本发明的另一实施例中，可以利用弯曲的入口盐水供给间隔件特征。这些特征可以沿着入口边缘和出口边缘印刷或沉积在膜页片的二分之一膜页片上，并且仅延伸足够远以提供对胶线区域的支撑。在卷起和粘合该元件的过程中，入口边缘和出口边缘处的弯曲特征44在尖端46彼此靠近的地方形成更紧密的图案，使得在卷起过程中，在螺旋卷绕元件被卷起时图案为相邻层提供支撑。在图5所示的本发明的另一实施例中，尖端46之间的间距可以减小到零，从而形成连续的实线48，该实线在卷起操作期间提供了对胶线的更完整的支撑。在元件的端部在修整线40处被修整之后，弯曲部分的更紧密的间隔被去除，这打开了特征之间的入口和出口间隔，从而促进流体流动并有助于避免元件端部处的压力损失。在传统的螺旋卷绕膜中，盐水在供给空间中的流动正交于元件的端部(流动矢量平行于中心管的轴线)，并且流体流中的材料可以堆叠在盐水供给通道的端部处，从而堵塞流体供给通道。元件的供给端部处的这种流体堵塞可以通过产生流体流动流来减轻，该流体流动流在与元件的中心线成一定角度的流动矢量上部分转向。在流体进入盐水供给空间时，通过产生流体的扫掠运动，可能已经积聚在供给空间的材料可以被清除。在图6中，转向页片60具有弯曲表面，这些弯曲表面在卷起元件的端部处施加了侧向流，以通过从螺旋卷绕元件的端面扫掠流体流中正在进入螺旋卷绕元件的盐水供给空间通道的固体来帮助避免元件的端部堵塞。图6的视图被示出为螺旋卷绕元件的平坦的、未卷起的视图。通常，这种图案被缠绕在中心管周围，但是在图6中被示出以更容易地描述该构思。盐水供给溶液66在其进入螺旋卷绕元件的端部时是处于法向的(平行于中心管的轴线)。转向页片60施加了穿过螺旋卷绕元件的端部的流动图案，从而防止材料积聚在盐水供给通道的端部上。在印刷间隔件64进入元件时，存在弯曲的入口部件62，该入口部件保持盐水供给溶液66与盐水供给溶液66的流动矢量一致。当盐水供给溶液进入膜供给空间时，印刷间隔件64有助于将盐水供给溶液66的流动矢量对齐更加平行于膜元件中心管的中心线。然而，熟悉现有技术的人将会知道，这些印刷间隔件64可以具有各种形状和构造，以激发局部涡旋并减少螺旋卷绕元件的盐水供给空间中的浓度极化。
这些特征可以通过多种技术来沉积。如胶版印刷、凹版印刷、和丝网印刷等传统印刷技术能够是合适的，尽管这些沉积技术可能存在厚度和几何形状限制性。较厚的特征可以通过微喷射、喷墨印刷、熔融沉积、光聚合物技术、热熔聚合物来沉积，或者通过使用粘合剂的应用来沉积，该应用可以包括片的辊转移或单个特征的拾放。
这些特征可以包括与分离的流体和渗透载体相容的任何数量的材料，包括但不限于热塑性塑料、反应性聚合物、蜡、或树脂。此外，与分离的流体相容但不到膜片的直接沉积物相容的材料(包括但不限于高温热塑性塑料、金属或陶瓷)可以预成型、铸造或切割成合适的尺寸，并且利用与膜片相容的粘合剂粘附到膜片的表面上。
已经结合各个示例实施例描述了本发明。将理解的是，以上描述仅用于说明本发明的原理的应用，本发明的范围由参照说明书的权利要求书来确定。本发明的其他变体和修改对于本领域的技术人员而言将是明显的。

Claims (22)

1.一种用于在螺旋卷绕过滤元件中使用的膜，该膜包括第一页片和第二页片，其中每个页片具有活性表面，该活性表面具有布置在该表面上的多个突起，这些突起被成形并布置在该表面上使得当该第一页片的活性表面邻近该第二页片的活性表面放置时，这些突起彼此接触，同时该第一页片上的突起通过该第二页片上的突起与该第二页片的活性表面分离；其中，该第一页片和该第二页片被放置为使得这些活性表面彼此面对并且通过突起而分离。
2.如权利要求1所述的膜，该膜包括膜材料片，其中该第一页片包括该膜材料片的第一部分；并且该第二页片包括该膜材料片的第二部分，该第二部分通过折线与该第一部分分离；并且其中该第一页片和该第二页片被放置为使得通过沿着该折线折叠该膜材料片，活性表面彼此面对。
3.如权利要求1所述的膜，其中这些突起包括多个线形突起，其中，这些线形突起彼此平行布置并且在相应页片的表面上的所有平面方向上彼此分离；并且其中，这些线形突起以与相应页片的供给边缘成除了90度之外的角度布置在表面上，使得该第一页片上的线形突起在它们的交点处接触该第二页片上的线形突起。
4.如权利要求3所述的膜，其中，该角度在40度与85度之间、或者在100度与135度之间。
5.如权利要求1所述的膜，其中，这些突起从每个页片的表面突出至少0.065mm、但不超过0.4mm。
6.如权利要求1所述的膜，其中，这些突起包括多个弯曲特征，这些弯曲特征被构造成使得当该膜螺旋卷绕时，该第一页片上的弯曲特征将以除了0度以外的角度与该第二页片上的弯曲特征相交。
7.如权利要求3所述的膜，其中，这些线形突起延伸穿过相应页片的整个宽度。
8.如权利要求3所述的膜，其中，这些线形突起延伸穿过的宽度小于相应页片的整个宽度。
9.如权利要求8所述的膜，其中，这些线形突起在轴向尺寸上至少为20mm长，并且线段之间的间距小于线段的长度。
10.如权利要求1所述的膜，其中，这些突起布置在该第一页片的第一区域中，并且布置在该第二页片的第一区域中，并且进一步包括多个流动突起，这些流动突起布置在(a)该第一页片的活性表面上而不是该第一页片的第一区域中，布置在(b)该第二页片的活性表面上而不是该第二页片的第一区域中，或者布置在(c)两者，其中这些流动突起具有的高度约等于该第一页片的第一区域中的突起的高度和该第二页片的第一区域中的突起的高度之和，并且其中当该元件螺旋卷绕时，一个页片上的流动突起不接触另一页片上的那些流动突起。
11.如权利要求10所述的膜，其中，这些流动突起布置在该第一页片上、而不是在该第二页片上。
12.如权利要求8所述的膜，其中，这些线形突起布置在最接近该相应页片的该供给边缘和拒收边缘的区域中，并且进一步包括多个流动突起，这些流动突起布置在(a)除了由这些线形突起占据的那些区域之外的区域中的该第一页片的活性表面上，布置在(b)除了由这些线形突起占据的那些区域之外的区域中的第二页片的活性表面上，或者布置在(c)两者，其中这些流动突起具有的高度约等于该第一页片上的线形突起的高度和该第二页片上的线形突起的高度之和；并且其中，当该元件螺旋卷绕时，一个页片上的流动突起不接触另一页片上的那些流动突起。
13.如权利要求12所述的膜，其中，这些流动突起布置在该第一页片上、而不是在该第二页片上。
14.一种制造膜的方法，包括
提供第一页片和第二页片，该第一页片和第二页片各自具有活性表面；
将多个突起放置在每个页片的活性表面上，这些突起被成形并布置在该表面上，使得当该第一页片的活性表面邻近该第二页片的活性表面放置时这些突起彼此接触，同时该第一页片上的突起通过该第二页片上的突起与该第二页片的活性表面分离；
将该第一页片的活性表面邻近该第二页片的活性表面、由这些突起分离地放置。
15.如权利要求14所述的方法，其中，提供第一页片和第二页片包括提供通过折线分成第一页片和第二页片的片；并且其中，将该第一页片的活性表面邻近该第二页片的活性表面放置包括沿着该折线折叠该片。
16.一种过滤元件，包括如权利要求1所述的膜，该膜螺旋卷绕在中心管周围。
17.一种流体处理系统，包括如权利要求16所述的多个过滤元件。
18.一种处理流体的方法，包括使流体流过如权利要求16所述的过滤元件。
19.一种用于在螺旋卷绕过滤元件中使用的膜，该膜包括具有活性表面的片，该片被折叠为使得该活性表面在该折叠片内侧，其中该活性表面具有布置在其上的多个突起，这些突起被成形并布置在该表面上，使得这些突起彼此接触并保持该折叠片中的面对的活性表面分开。
20.如权利要求19所述的膜，其中，这些突起包括多个线形突起，这些线形突起以与该膜的供给边缘成除了90度之外的角度布置在该活性表面上。
21.如权利要求20所述的膜，其中，该角度在40度与85度之间、或者在100度与135度之间。
22.如权利要求20所述的膜，其中，这些突起从每个页片的表面突出至少0.065mm、但不超过0.4mm。
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