CN114514064B - Impregnated flat membrane element and method for manufacturing same - Google Patents

Impregnated flat membrane element and method for manufacturing same Download PDF

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Publication number
CN114514064B
CN114514064B CN202080066582.7A CN202080066582A CN114514064B CN 114514064 B CN114514064 B CN 114514064B CN 202080066582 A CN202080066582 A CN 202080066582A CN 114514064 B CN114514064 B CN 114514064B
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Prior art keywords
water
concave cross
section
separation membrane
peel strength
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CN114514064A (en
Inventor
桧垣绫乃
森田纯辅
东昌男
岛田宪史
高杉健
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Dongyang Textile Mc Co ltd
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Dongyang Textile Mc Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D69/00Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/06Flat membranes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D63/00Apparatus in general for separation processes using semi-permeable membranes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D63/00Apparatus in general for separation processes using semi-permeable membranes
    • B01D63/08Flat membrane modules
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D67/00Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0002Organic membrane manufacture
    • B01D67/002Organic membrane manufacture from melts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00Technologies for wastewater treatment
    • Y02W10/10Biological treatment of water, waste water, or sewage

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

To provide an immersed flat membrane element and a method for manufacturing the same, wherein the peeling strength and cross-sectional profile of a single water-stop portion formed by joining a separation membrane to the peripheral portion of a filter plate are designed so that breakage of the separation membrane can be prevented even when only the water-permeable portion side of the water-stop portion is partially peeled off, the filtering performance can be maintained for a long period of time, and the service life can be prolonged by repairing the peeling of the water-permeable portion side of the water-stop portion. A immersed flat membrane element in which a separation membrane is joined along the entire periphery of the periphery of a resin filter plate to form a water-stop portion, wherein the water-stop portion is formed of a single continuous line of concave cross section, the peel strength of a welded portion (1) of a shoulder portion of the concave cross section on the water-permeable portion side forming the water-stop portion is 30 to 90% of the peel strength of a welded portion (2) of a shoulder portion of the concave cross section on the outer side of the filter plate forming the water-stop portion, and the peel strength of the welded portion (2) of the water-stop portion is 8N to 40N.

Description

Impregnated flat membrane element and method for manufacturing same
Technical Field
The present invention relates to an immersed flat membrane element of a membrane separation device used in a membrane bioreactor method, and more particularly, to a method for prolonging the service life of a membrane separation device by designing the peel strength and cross-sectional profile of a water stop portion formed by joining separation membranes to the peripheral portion of a filter plate, and preventing the separation membranes from being broken entirely when peeled off from the water permeable portion side of the water stop portion, thereby maintaining the filtration performance of the flat membrane element for a long period of time, and repairing only the water permeable portion side of the water stop portion.
Background
In recent years, the quality and quantity of domestic water and industrial water have been increased against the background of the increase in world population, industrialization, urbanization, and improvement in living standards. The membrane bioreactor method is a technology that has been attracting attention in recent years because a separation membrane is used to filter water treated with activated sludge, and thus a clear filtrate can be obtained, and the membrane bioreactor method has advantages such as compactness of equipment and easy operation and management. Examples of the solid-liquid separation apparatus used in the membrane bioreactor method include an immersed membrane separation apparatus as shown in fig. 1. In fig. 1, a membrane separation device 1 includes a flat membrane element 2 and a gas diffusion device 3.
As shown in fig. 2, the flat membrane element 2 is formed by disposing separation membranes 5 on the front and rear surfaces of a filter sheet 4 made of thermoplastic resin, and bonding the filter sheet 4 along the entire periphery of the peripheral portion thereof. The activated sludge-treated water is filtered by the surface surrounded by the joint portion of the separation membrane 5. The surface covered by the joint is called a water permeable part. The separation membrane 5 is formed by impregnating a nonwoven fabric as a base material with a membrane polymer. The flat membrane element 2 is configured to adhere and accumulate sludge and foreign matters on the membrane surface of the water permeable portion by suction filtration during operation, but the membrane surface is cleaned by bubbles ejected from the gas diffusion device 3 and upward flow generated by the bubbles, and the sludge and foreign matters adhering and accumulated on the membrane surface are removed, thereby preventing degradation of the filtration performance of the flat membrane element.
However, there is a problem in that the separation membrane swings due to the impact of the collision with the bubbles and the upward flow, a load is generated at the joint portion between the filter sheet and the separation membrane, the separation membrane peels off, and the sludge leaks to the water permeable side. Among the bonding methods of the filter sheet and the separation membrane, there is an ultrasonic bonding method. The filter plate resin and the separation membrane are melted by heat generated by ultrasonic vibration by pressing a horn of an oscillating ultrasonic wave against a portion to be joined, and the resin and the separation membrane are welded.
As shown in fig. 3, when the welding between the filter sheet and the separation membrane is weak, there is a problem in that the separation membrane is easily peeled off from the filter sheet due to the swing of the membrane during the cleaning of the membrane surface. If leakage of sludge to the water permeable side due to separation of the separation membrane during activated sludge treatment is not prevented in 90% or more of the flat membrane elements in the membrane separation device, it is not practical. On the other hand, if the fusion bonding is too strong, the melted filter sheet resin solidifies in a state of reaching deep inside the separation membrane at the time of fusion bonding, and as a result, there is a problem that the fusion bonded portion of the filter sheet and the separation membrane is easily broken.
In order to solve such a problem, patent document 1 discloses a technique of suppressing separation of the filter sheet and the separation membrane and breakage of the separation membrane by forming a molten margin on the outside of the filter sheet higher than a molten margin on the water permeable portion side. However, in the invention described in patent document 1, if the molten margin is destroyed, it is difficult to repair the peeled separation membrane partially and reuse it. In addition, a plurality of water stop portions must be provided independently on the same surface of the flat membrane element, and the operation for manufacturing the flat membrane element is complicated. Therefore, in the case of welding, particularly in the water-stop portion on the water-permeable portion side, a contact failure of the ultrasonic oscillation horn tends to occur, and there is a problem that a large difference in welding strength cannot be provided between the plurality of water-stop portions.
In patent document 2, the rupture of the separation membrane at the time of use is prevented by setting appropriate welding conditions under which the nonwoven fabric layer does not reach, but it is practically difficult to completely prevent the rupture of the separation membrane, separation of the separation membrane is easily caused under the welding conditions under which the rupture of the separation membrane is prevented, and the rupture of the separation membrane is easily caused under the welding conditions under which the separation of the separation membrane is prevented, so that both are prevented at the same time (fig. 3).
Prior art literature
Patent literature
Patent document 1: japanese patent No. 3576050
Patent document 2: japanese patent No. 3778758
Disclosure of Invention
Problems to be solved by the invention
The present invention has been made in view of the above-described problems of the prior art, and an object of the present invention is to provide an immersed flat membrane element and a method for manufacturing the same, which are capable of preventing breakage of a separation membrane even when only a water-permeable portion side of the water-impermeable portion is partially peeled off by designing a peeling strength and a cross-sectional profile of a single water-impermeable portion formed by joining separation membranes to a peripheral portion of a filter plate, maintaining filtration performance for a long period, and prolonging a service life by repairing the peeling of the water-permeable portion side of the water-impermeable portion.
Means for solving the problems
The present inventors have made intensive studies on the relationship between peel strength and shape of an ultrasonic horn, and as a result, have found that by providing a single water stop portion having a continuous concave cross section using an ultrasonic horn having a specific cross section, the strength of a welded portion of the water stop portion can be appropriately set on the water permeable portion side and the outside of a filter sheet, and thus, an immersed flat membrane element having both durability and repairability of the water stop portion can be easily manufactured, and completed the present invention.
That is, the present invention has the following configurations (1) to (5).
(1) An immersed flat membrane element, characterized in that a resin separation membrane is bonded along the entire periphery of a resin filter plate to form a water-stop portion, the water-stop portion is formed of a single continuous line of concave cross section, the peel strength of a welded portion 1 forming a shoulder portion of the concave cross section on the water-permeable portion side of the water-stop portion is 30-90% of the peel strength of a welded portion 2 forming a shoulder portion of the concave cross section on the outer side of the filter plate of the water-stop portion, and the peel strength of the welded portion 2 of the water-stop portion is 8N to 40N.
(2) The immersed flat membrane element according to (1), wherein the raised portion of the shoulder portion of the concave cross section on the water-permeable portion side of the water-stop portion is curved, and the raised portion of the shoulder portion of the concave cross section on the outside of the filter sheet of the water-stop portion is raised from the flat portion by a significant upward angular change from the flat portion at the outside end of the filter sheet of the flat portion between both shoulder portions of the concave cross section, and the edge angle of the angular change is 80 degrees to 135 degrees.
(3) The immersed flat film element according to (1) or (2), wherein the peel strength of the welded portion 1 is 30N or less.
(4) The method for producing an immersed flat membrane element according to any one of (1) to (3), comprising a step of forming a water-stop portion, wherein a resin separation membrane is superposed on a resin filter sheet, an ultrasonic horn is pressed down from the separation membrane side along the entire periphery of the superposed peripheral portion to form a water-stop portion composed of continuous lines of a single concave cross section, and a portion of the ultrasonic horn pressed down has a convex shape corresponding to the concave cross section of the water-stop portion.
(5) The method according to (4), wherein the portion of the ultrasonic horn pressed down further includes a pattern portion continuous with the convex shape portion corresponding to the concave cross section of the water stop portion.
Effects of the invention
(1) The immersed flat membrane element of the present invention is capable of maintaining the filtration performance of the flat membrane element by properly controlling the peel strength between the water permeable portion side of the welding portion of the water stop portion having a single concave cross section and the outside of the filter sheet, thereby suppressing deterioration of the separation membrane due to heat at the time of welding at the time of use, preventing breakage of the separation membrane at the time of use, and maintaining the water stop function at the outside of the filter sheet even when the water permeable portion side of the water stop portion is partially peeled off after long-term use, thereby enabling the service life obtained by partial repair to be prolonged.
(2) In the immersed flat membrane element according to the present invention, the raised portion of the concave portion having the cross-sectional shape of the water stop portion is curved, and the raised portion of the shoulder portion having the concave cross-section outside the filter sheet of the water stop portion is raised by a significant upward angular change from the flat portion at the end outside the filter sheet of the flat portion between the two shoulder portions having the concave cross-section, and the edge angle forming the angular change is controlled to be within a specific range, so that the separation membrane structure is maintained as far as possible inside the water stop portion, and sufficient welding strength to prevent separation membrane separation can be achieved, and the above-described effects can be easily obtained.
(3) In the method for manufacturing an immersed flat membrane element according to the present invention, since an ultrasonic horn having a specific shape is used, a single concave water stop portion having the above-described effect can be formed on the smooth surface of the filter sheet by one welding operation, and the processing cost of the filter sheet, the welding man-hour, and the power supply capacity can be reduced.
Drawings
FIG. 1 is a schematic diagram of a prior art immersion type membrane separation apparatus.
Fig. 2 is a schematic view of a prior art flat membrane element.
Fig. 3 is a schematic view showing a problem of peeling of a water stop portion in the prior art.
Fig. 4 is a view showing the structure of the flat membrane element of the present invention.
Fig. 5 is a schematic drawing of a portion of a flat membrane element of the invention in enlargement.
Fig. 6 is a cross-sectional photograph of a water stop portion of a flat membrane element of the present invention.
Fig. 7 is a graph showing peel strength distribution of a water stop portion of a flat membrane element according to the present invention.
Fig. 8 is a schematic cross-sectional view of a water stop portion of a flat membrane element of the present invention.
Fig. 9 is a schematic view of an ultrasonic horn for use in the present invention.
Fig. 10 is a schematic cross-sectional view of the water stop portion in a state where the ultrasonic horn is applied.
Detailed Description
Embodiments of the immersed flat membrane element according to the present invention will be described with reference to the accompanying drawings.
Fig. 4 is a schematic view of an example of the immersed flat membrane element of the present invention. As shown in fig. 4, the immersed flat membrane element of the present invention is preferably configured such that a resin mesh is disposed as a flow path material 11 in a central portion 10 of a filter sheet 4, a buffer material 12 is disposed thereon, and a separation membrane 5 is bonded thereon along a peripheral portion 7 of the filter sheet 4. In the present invention, the separation membrane 5 is pressed against the flow path material 11 during suction filtration, and therefore, it is preferable to dispose the buffer material 12 having a membrane protecting effect therebetween. In fig. 4, only one side of the filter sheet 4 of the immersed flat membrane element is shown, but in the present invention, both sides of the filter sheet 4 are preferably formed in the same manner.
When the flow of the membrane-permeated water in the immersed flat membrane element of the present invention is described with reference to fig. 4, the liquid to be treated is brought into contact with the outer surface of the separation membrane 5, suction filtration is performed from the outer side to the inner side of the separation membrane 5, and the membrane-permeated water after filtration is discharged from the permeate intake 13 to the outside of the immersed flat membrane element while sequentially passing through the buffer material 12 and the gaps in the flow path material 11 arranged between the separation membrane 5 and the filter sheet 4, in the direction of the permeate intake 13 attached to the end of the filter sheet 4.
In the immersed flat membrane element of the present invention, the peripheral portion 7 of the filter sheet 4 is preferably located 0.6 to 2mm higher than the central portion 10, and the flow path material 11 and the buffer material 12 are preferably disposed in the recess space of the central portion 10 formed by this, so that the difference in height between the central portion 10 and the peripheral portion 7 in the state where the flow path material 11 and the buffer material 12 are disposed is preferably 0.5mm or less. The buffer material 12 is preferably disposed so as to cover the flow path material 11 bonded to the filter sheet 4, and is bonded to the flow path material 11. The separation membrane 5 is preferably bonded to the peripheral portion 7 so as to cover the filter sheet 4 provided with the flow channel material 11 and the buffer material 12.
In the present invention, the material of the separation membrane 5 is not particularly limited as long as it is made of a resin, and for example, a plastic resin such as polyvinyl chloride, chlorinated polyvinyl chloride, polyether sulfone, polyvinylidene fluoride, polytetrafluoroethylene, or the like, or a resin composed of a mixture of these resins can be suitably selected. The separation membrane 5 may be a nonwoven fabric made of a thermoplastic resin such as PET or polypropylene, or a composite membrane in which a paper is impregnated with or laminated with a separation layer made of the membrane material. The thickness of the separation membrane 5 is preferably 50 μm to 300. Mu.m, more preferably 80 μm to 150. Mu.m. If the thickness is too large, uneven welding or peeling from the filter sheet is likely to occur. In addition, when the thickness is small, breakage of the separation membrane is likely to occur.
The material of the filter sheet 4 is not particularly limited as long as it is made of a resin that retains the entire shape of the flat membrane element, and for example, a thermoplastic resin such as ABS resin, polyvinyl chloride resin, or polycarbonate resin can be suitably selected. The filter plate has a rectangular shape with a height (length) of 300mm to 1500mm and a width of 200mm to 550mm, and preferably has a peripheral portion 7 with a width of 10mm to 20 mm.
In the present invention, it is preferable that the filter sheet and the separation membrane are arranged so that the peripheral portion 7 of the filter sheet and the separation membrane 5 are overlapped with each other by a width of about 5 to 15mm, and then welded by ultrasonic welding at an outer position of 0.5mm or more from the inner end portion of the peripheral portion 7. Fig. 5 is an explanatory view showing the water stop portion 6 and the welding auxiliary portion 8 in the peripheral portion 7 in a state where the filter sheet 4 and the separation membrane 5 are offset in order to facilitate understanding of the welded portion of the filter sheet 4 and the separation membrane 5. In the present invention, a single continuous water-stopping portion 6 (welded portion) having a width of 0.5mm to 3mm and a maximum depth of 50 μm to 500 μm is preferably integrally formed over the entire circumference along the peripheral portion 7 of the filter sheet 4 by using a photovoltaic horn. In order to prevent the outer side Zhou Shandong of the separation membrane 5 from being used, it is preferable to provide a patterned welding auxiliary portion 8 outside the water stop portion 6.
Fig. 6 is a cross-sectional view of the vicinity of the water stop 6 of the cut-off peripheral portion 7 in the width direction. In the present invention, the water stop portion 6 is constituted by a continuous line having a concave cross section shown by double arrow a in fig. 6, which line constitutes a closed rectangle along the peripheral portion 7. The water stop portion 6 is a welded portion formed by welding the filter sheet 4 and the separation membrane 5, and the welded portion is a portion that exhibits peel strength when the filter sheet 4 and the separation membrane 5 are peeled off. Fig. 7 is a graph showing a peel strength distribution when the separation membrane 5 is peeled from the water permeable portion side (the inside of the peripheral portion) to the outside of the filter sheet (the outside of the peripheral portion) in fig. 6. The separation film 5 is stretched by the tensile stress in the peeling test, and therefore the tensile distance at which the peeling strength is developed is longer than the length of the actual a.
In the flat membrane element of the present invention, there are 2 peaks (peak 1, peak 2) as shown in fig. 7 in the peel strength distribution diagram of the water stop portion. Peak 1 is the peel strength of welded portion 1 of the shoulder portion of the concave cross section on the water-permeable portion side forming the water-stop portion shown in fig. 8, and peak 2 is the peel strength of welded portion 2 of the shoulder portion of the concave cross section on the filter sheet outer side forming the water-stop portion. Such a peel strength profile is closely related to the shape of the undulating horn when the separation film is welded to the peripheral portion, and is a characteristic property of the immersed flat film element of the present invention.
As shown in fig. 7, the flat film element of the present invention is characterized in that the peel strength (peak 1) of the welded portion 1 is set to be relatively weak, while the peel strength (peak 2) of the welded portion 2 is set to be stronger than the peel strength (peak 1) of the welded portion 1. That is, in the welding portion 1, as will be described later, by using an ultrasonic horn having a specific shape on the welding portion 1 side, the filter sheet and the separation membrane are in a state of being fusion-bonded widely and shallowly to each other. Therefore, the welded portion 1 is suppressed in deterioration of the separation film and has a relatively weak peel strength as compared with the welded portion 2. Thus, when the separation membrane of the water permeable portion swings to form stress during the activated sludge treatment, the separation membrane can be effectively prevented from breaking at the welded portion 1, which is the boundary between the water stop portion and the water permeable portion, which receives the maximum load. On the other hand, in the welding portion 2, since the ultrasonic horn having a specific shape on the welding portion 2 side is used, the filter sheet and the separation membrane are melted more than the welding portion 1, and are firmly integrated. Therefore, the weld 2 has a stronger peel strength than the weld 1. Thus, even if the separation film peels off at the welding portion 1, the separation film can be prevented from easily peeling off from the filter sheet at the welding portion 2. With such a configuration, even when the separation membrane is peeled off from the peripheral portion of the filter sheet at the welding portion 1, the function as an immersed flat membrane element can be maintained at the welding portion 2.
In the flat film element of the present invention, the peel strength of the welded portion 1 of the water-stop portion is 30 to 90%, preferably 35 to 85%, of the peel strength of the welded portion 2. If the ratio of the peel strength of the welded portion 1 is smaller than the above range, the peel strength of the welded portion 1 is insufficient, and the welded portion 1 is easily peeled off when the flat film element is handled. If the ratio is greater than the above range, the effect of the present invention cannot be sufficiently obtained.
In the present invention, the peel strength of the welded portion 2 of the water-stop portion is 8N to 40N, preferably 11N to 35N. If the peeling strength of the welded portion 2 is too small, film peeling is likely to occur in the welded portion 2 when film peeling or the like occurs in the welded portion 1. On the other hand, if the peel strength of the welded portion 2 is increased to excessively melt the interface between the separation membrane and the filter sheet resin, the structure of the separation membrane at the welded portion deteriorates, the breaking strength of the separation membrane is significantly reduced, and membrane breakage is likely to occur.
In the present invention, the peel strength of the fusion-spliced portion 1 of the water-stop portion is preferably 30N or less, more preferably 27N or less. The peel strength of the fusion-spliced portion 1 of the water-stop portion is preferably 4N or more, and more preferably 5N or more. If the peel strength of the welded portion 1 is too high, the occurrence of film peeling is reduced, but film breakage is likely to occur. On the other hand, if the peel strength of the fusion-bonded portion 1 is too small, film peeling is likely to occur.
As described above, by providing the welding portion 1 having a relatively weak peel strength on the water-permeable portion side of the water-stop portion and providing the welding portion 2 having a relatively strong peel strength on the outside of the filter sheet of the same water-stop portion, degradation of the separation membrane at the time of welding can be prevented on the water-permeable portion side of the water-stop portion, breakage of the separation membrane can be prevented on the water-permeable portion side where the load is largest at the time of use, and separation of the separation membrane from the filter sheet can be prevented, so that the filtration performance of the flat membrane element can be maintained for a long period of time. In addition, when the separation membrane and the filter sheet are partially peeled off only at the welded portion 1, it is possible to achieve a longer lifetime of the flat membrane element by repairing the same during inspection.
The shape of the water stop portion of the flat membrane element of the present invention has the following characteristics. That is, in the water stop portion of the present invention, the raised portion of the shoulder portion (welded portion 1) of the concave cross section on the water permeable portion side of the water stop portion is formed in a curve as shown in fig. 10E, and the raised portion of the shoulder portion (welded portion 2) of the concave cross section on the outside of the filter sheet of the water stop portion is raised by a significant upward angular change at the outside end (C of fig. 10) of the filter sheet of the flat portion (B of fig. 10) between the two shoulder portions. The edge angle (X in fig. 8) of the angle change of the elevated portion forming the welding portion 2 is preferably 80 degrees or more and 135 degrees or less. On the other hand, in order to form the cross section of the welding portion 1, it is preferable to use an ultrasonic horn having a curve with a cross section shape of 0.3 to 3mm in radius of curvature and 0.4 to 4mm in arc length on the welding portion 1 side. By providing the water stop portion with such a shape, when the separation film is stretched due to the formation of the water stop portion having a concave cross section at the time of welding, the degree of stretching of the separation film is dispersed widely at the welding portion 1 of the water stop portion, so that the separation film at the time of welding can be effectively prevented from being degraded, and the influence of peeling of the welding portion 1 can be stopped at the C position of fig. 10, and the progress of peeling of the separation film from the filter sheet can be completely prevented at the welding portion 2 having a stronger peeling strength.
The method for producing a flat membrane element according to the present invention preferably includes the steps of: the separation membrane is stacked on the resin filter sheet, and an ultrasonic horn (ultrasonic horn) is pressed down with a constant pressure along the entire circumference of the stacked peripheral portion, friction heat is generated at the interface between the filter sheet and the separation membrane, and the resin constituting the filter sheet and the separation membrane is melted, thereby forming a water-stop portion (welded portion) composed of a line of single concave cross sections. The ultrasonic horn 9 is preferably formed of a portion where the filter sheet 4 and the separation membrane 5 overlap each other, a portion where the water stop portion 6 shown on the right side in fig. 9 is formed, and a portion where the outer periphery of the separation membrane 5 is formed with a pattern-shaped welding auxiliary portion 8 for preventing the outer periphery from shaking. The ultrasonic horn 9 is pressed into the peripheral portion of the filter plate at a set horn speed in the direction of the arrow in fig. 9. As shown in fig. 10, the molten resin in the peripheral portion of the filter sheet flows to both sides of the press-fit horn to rise. In this case, the peel strength of the region E, B, D of the water stop portion in fig. 10 is strongly affected by the ultrasonic horn in the order of region D > region E > region B, so that the peel strength distribution diagram shown in fig. 7 can be obtained.
In order to exhibit such a peel strength distribution, an ultrasonic horn having such a shape as described above may be used, and the ultrasonic frequency, the ultrasonic oscillation time, the applied pressure, and the like may be set in specific appropriate ranges. Specifically, the ultrasonic frequency is preferably 15 to 70kHz, more preferably 15 to 50kHz, and still more preferably 15 to 30kHz. The applied pressure is preferably 0.1 to 3.0MPa, more preferably 0.5 to 2.5MPa, and the oscillation time is preferably 0.3 to 1.5 seconds, more preferably 0.4 to 1.0 seconds. If the applied pressure is small, the adhesion between the peripheral portion of the filter sheet and the separation membrane becomes weak (the bonding head cannot sink into the filter sheet), and therefore uniform welding cannot be obtained. If the applied pressure is large, the load of the ultrasonic oscillator increases and the life is shortened. If the oscillation time is short, heat generation is insufficient at the friction interface between the separation membrane and the filter sheet, and welding unevenness may occur. If the oscillation time is long, the melting of the filter sheet resin and the separation membrane becomes excessive, and the peel strength becomes weak.
In the flat membrane element of the present invention, since the flat membrane element is configured as described above, the welded portion 1 on the water-permeable portion side of the water-stop portion is not broken, and even if the welded portion 1 peels off due to long-term use, the welded portion 2 on the filter sheet side is kept from peeling off, so that a long life can be achieved only by partial repair of the welded portion 1.
Examples
The flat membrane element of the present invention is shown by way of example, but the present invention is not limited thereto. The peel strength of the present invention was evaluated by the following method.
(peel Strength)
The peel strength of the welded portions 1 and 2 was measured by using a flat film element in an unused state after ultrasonic welding, based on the procedure shown below. The welded part was cut so that the length direction of the water stop was 15mm wide, a water permeable part of the separation membrane 2cm away from the water stop was provided on a gripper at the upper part of a tensile testing machine (Shimadzu AutographAGS-J,50N load cell), and a filter sheet welded with the separation membrane was provided on a gripper at the lower part. 180-degree peeling was performed at 20mm/min, and the tensile force (N) at this time was measured. The peeling direction is performed in a direction from the water permeable portion side of the flat membrane element toward the peripheral portion side. The peel strength of the welded portion 1 was measured by reading the peak top on the water permeable portion side, and the peel strength of the welded portion 2 was measured by reading the peak top on the outside of the filter sheet.
(leakage inhibition Rate of sludge toward Water permeable side)
Regarding the leakage inhibition rate of the sludge to the water permeable side, 10 pieces of Ping Mo elements were continuously operated in the aeration tank for 3 months, and the transparent suction pipe connected to the permeate intake port 13 was visually observed periodically during use to confirm whether or not there was a flat membrane element leaking the sludge to the water permeable side, and the ratio of the number of flat membrane elements not leaking the sludge out of the 10 pieces of flat membrane elements used was regarded as the inhibition rate (%) of the leakage of the sludge to the water permeable side.
(whether or not separation film is peeled off or broken)
The ratio (%) of the separation film to the 10 Ping Mo elements used was shown when the separation film was peeled off or broken by visual observation.
(whether or not reuse by repair is possible)
In the case where the separation film is peeled off or broken, the separation film is welded again to the welded portion where the separation film is peeled off or broken, and when the peeling strength of the welded portion is recovered to 90% or more of the initial strength, the separation film is judged to be acceptable, and when the separation film is less than 90% the separation film is judged to be unacceptable.
Example 1
(separation Membrane)
After cutting the PET paper to a predetermined size, the PET paper is fixed to a frame for film formation while avoiding wrinkling. Next, the PET paper was immersed in a solution (film-forming stock solution) composed of 7.5 mass% of chlorinated polyvinyl chloride, 63.3 mass% of tetrahydrofuran, 19 mass% of isopropyl alcohol, and 10.2 mass% of 1-butanol, and left standing for 1 minute. Then, the PET paper impregnated with the film-forming stock solution was slowly taken out, and then left to stand in a drying zone (in a constant temperature and humidity box) having a relative humidity of 75% and a temperature of 20℃for 10 minutes, thereby forming a separation film.
(production of Filter plate)
The filter sheet made of ABS resin (315 mm in height and 225mm in width) was joined to both front and back surfaces thereof with a gap-free peripheral portion made of ABS resin (12.5 mm in width), whereby a filter sheet having a thickness of 6mm in the peripheral portion and a height of 1mm in the peripheral portion was produced.
(production of flat film element)
A resin mesh is provided as a runner material in the central portion of the filter sheet: DOP-18K (290 mm in height and 200mm in width) from Filcon, japan was bonded to the filter plate with a water-resistant bonding agent to form a membrane permeate channel. The filter sheet and the resin mesh were joined, and a nonwoven fabric made of PET was provided on the upper surface of the resin mesh: as a buffer material, widely used paper (product) was 05TH-60 (height 285mm, width 195 mm). Then, the separator (height 305mm, width 215mm, thickness 0.13 mm) was overlapped with the peripheral portion of the filter plate from the upper portion of the nonwoven fabric, and the relief horn shown in FIG. 9 was pressed down to weld the peripheral portion and the separator.
The relief horn used was a horn having a radius of curvature of 1mm at the tip of the water permeable portion side (inner elevated portion), an arc length of 1.6mm, and an edge angle of 90 degrees at the outside of the filter sheet (outer elevated portion). The applied pressure of the undulating horn was 0.8MPa, the oscillation frequency of the ultrasonic wave was 20kHz, and the oscillation time was 0.475 seconds.
The separation membrane was bonded to the back surface in the same manner, and a flat membrane element was fabricated.
Example 2
A flat membrane element was produced in the same manner as in example 1, except that the oscillation time was set to 0.50 seconds.
Example 3
A flat membrane element was produced in the same manner as in example 1, except that the oscillation time was set to 0.65 seconds.
Example 4
A flat film element was produced in the same manner as in example 2, except that the front end on the water-permeable portion side (inner elevated portion) had a larger radius of curvature (2 mm) than that used in example 1.
Example 5
A flat film element was produced in the same manner as in example 1, except that the tip of the water-permeable portion side (inner elevated portion) had a smaller radius of curvature (0.6 mm) than that used in example 1.
Example 6
A flat membrane element was produced in the same manner as in example 5, except that the oscillation time was set to 0.40 seconds.
Example 7
A flat film element was produced in the same manner as in example 1 except that the oscillating time was set to 0.80 seconds using a smaller radius of curvature (0.8 mm) of the tip on the water-permeable portion side (inner elevated portion) as the undulating horn than that used in example 1.
Comparative example 1
A flat membrane element was produced in the same manner as in example 1, except that a horn having an edge angle of 90 degrees on the water permeable portion side (inner elevated portion) and an edge angle of 90 degrees on the outside of the filter sheet (outer elevated portion) was used as the undulation horn, and the oscillation time was set to 0.40 seconds.
Comparative example 2
A flat membrane element was produced in the same manner as in example 3 (in other words, oscillation time was 0.60 seconds) except that a horn having an edge angle of 90 degrees on the water permeable portion side (inner elevated portion) and an edge angle of 90 degrees on the outside of the filter sheet (outer elevated portion) was used as the undulation horn.
Comparative example 3
A flat membrane element was produced in the same manner as in example 3, except that a horn having an edge angle of 90 degrees with respect to the water permeable portion side (inner elevated portion) and an edge angle of 160 degrees with respect to the outside of the filter sheet (outer elevated portion) was used as the undulation horn.
Details and evaluation results of the flat membrane elements of examples 1 to 7 and comparative examples 1 to 3 are shown in table 1.
[ Table 1 ]
From the results of table 1, it is clear that in examples 1 to 7, flat film elements having excellent durability and easy repair were obtained. In examples 1, 2 and 4, the separation membrane was peeled off from the filter sheet at a part of the welded portion 1 during operation, but the liquid to be treated did not leak to the water permeable side, and the flat membrane element was reused by repairing the re-welding of the welded portion 1. In example 6, the sludge leakage inhibition rate was as high as 90%, and although both the welded portions 1 and 2 were peeled off, the flat membrane element was reused after repair. On the other hand, in comparative example 1 in which the peel strength of the welded portions 1 and 2 was low, in the flat film element of 60%, the welded portions 1 and 2 were each subjected to film peeling, and the sludge leakage inhibition rate was as low as 40%. In comparative example 2, the welded portion 1 subjected to the load caused by the swing during use was probably because the separation membrane was too severely degraded during welding, and the welded portion 1 was broken (membrane breakage) in 30% of the flat membrane elements, and could not be used after repair. In comparative example 3, the welding shapes of the welding portion 1 and the welding portion 2 were replaced, but the breakage (film breakage) of the welding portion 1 was observed in 20% of the flat film elements under the influence of the swing at the time of use as in comparative example 2, and the use was not possible after repair.
Industrial applicability
The immersed flat membrane element of the present invention is designed for the peel strength and the cross-sectional profile of the water stop portion having a single continuous concave cross-section formed by joining the separation membrane to the peripheral portion of the filter plate, and therefore, can achieve both durability and easy repair, and can achieve an extended service life. Therefore, the immersed flat membrane element is suitable for the field of water treatment, and is particularly suitable for wastewater treatment.
Symbol description
1. Membrane separation device
2. Flat membrane element
3. Gas diffusion device
4. Filter plate
5. Separation membrane
6. Water stop part
7. Peripheral portion
8. Welding auxiliary part
9. Ultrasonic welding head
10. Central portion
11. Runner material
12. Cushioning material
13. Permeable water intake

Claims (5)

1. An immersed flat membrane element, characterized in that a resin separation membrane is joined along the entire periphery of the periphery of a resin filter plate to form a water stop, wherein the water stop is formed of a single continuous line of concave cross sections, the rise of the shoulder of the concave cross section on the water permeable side of the water stop is curved, the rise of the shoulder of the concave cross section on the outside of the filter plate of the water stop is raised by a significant upward angle change from the flat at the outside end of the flat filter plate between the two shoulders of the concave cross section, the peel strength of the welded portion 1 of the shoulder of the concave cross section on the water permeable side of the water stop is 30 to 90% of the peel strength of the welded portion 2 of the shoulder of the concave cross section on the outside of the filter plate of the water stop, and the peel strength of the welded portion 2 of the water stop is 8N to 40N.
2. The immersed flat membrane element according to claim 1, wherein an edge angle forming the angle change is 80 degrees or more and 135 degrees or less.
3. The immersed flat film element according to claim 1 or 2, wherein the peel strength of the welded portion 1 is 30N or less.
4. A method for producing an immersed flat membrane element according to any one of claims 1 to 3, comprising a step of forming a water-stop portion by superposing a resin separation membrane on a resin filter sheet, pressing down an ultrasonic horn from the separation membrane side along the whole circumference of the superposed peripheral portion to form the water-stop portion composed of continuous lines of a single concave cross section,
the portion of the ultrasonic horn pressed down has a convex shape corresponding to the concave cross section of the water stop portion.
5. The method according to claim 4, wherein the portion of the ultrasonic horn pressed down further includes a pattern portion continuous with the convex shape portion corresponding to the concave cross section of the water stop portion.
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