Patent Publication Number: US-11376552-B2

Title: Permeate flow paterns

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a national stage application under 35 U.S.C. 371 of PCT application PCT/US2017/052116 filed 18 Sep. 2017, which claims priority to U.S. provisional application 62/397,142, filed 20 Sep. 2016. Each of the foregoing is incorporated by reference herein. 
     The present invention is related to that described in U.S. provisional 61/771,041, filed Feb. 28, 2013, and PCT/IB2014/060705, which are incorporated herein by reference. 
    
    
     BACKGROUND 
     Field of the Invention 
     The subject invention relates to a permeable membrane system utilized for the separation of fluid components, specifically spiral-wound membrane permeable membrane elements. 
     Description of Related Art 
     Spiral-wound membrane filtration elements well known in the art consist of a laminated structure comprised of a membrane sheet sealed to or around a porous permeate spacer which creates a path for removal of the fluid passing through the membrane to a central tube, while this laminated structure is wrapped spirally around the central tube and spaced from itself with a porous feed spacer to allow axial flow of the fluid through the element. While this feed spacer is necessary to maintain open and uniform axial flow between the laminated structure, it is also a source of flow restriction and pressure drop within the axial flow channel and also presents areas of restriction of flow and contact to the membrane that contribute significantly to membrane fouling via biological growth, scale formation, and particle capture. In pressure retarded osmosis (PRO), forward osmosis (FO), and reverse osmosis (RO) applications, flow paths in the feed spaces and the permeate spacer can be beneficial to optimal system operation. 
     Improvements to the design of spiral wound elements have been disclosed by Barger et al. and Bradford et al., which replace the feed spacer with islands or protrusions either deposited or embossed directly onto the outside or active surface of the membrane. This configuration is advantageous in that it maintains spacing for axial flow through the element while minimizing obstruction within the flow channel. It also eliminates the porous feed spacer as a separate component, thus simplifying element manufacture. Patent publication number US2016-0008763-A1, incorporated herein by reference, entitled Improved Spiral Wound Element Construction teaches the application of printed patterns on the back side of the active surface of the membrane sheet, or directly on the surface of the permeate spacer. 
     The following references, each of which is incorporated herein by reference, can facilitate understanding of the invention: U.S. Pat. Nos. 3,962,096; 4,476,022; 4,756,835; 4,834,881; 4,855,058; 4,902,417; 4,861,487; 6,632,357; and US application 2016-0008763-A1. 
     DESCRIPTION OF THE INVENTION 
     In some spiral-wound membrane separation applications which involve serial flow through the permeate spacer layer of successive elements such as in the PRO patent listed above, it is advantageous to have lower resistance to flow than what is exhibited by traditional woven permeate spacer fabrics, while maintaining other characteristics including resistance to deformation under high external pressure. Additionally, the ability to tailor flow channels of arbitrary shape within the permeate spacer can allow for controllable distribution of flow through the permeate spacer layer. Embodiments of the present invention provide features printed, deposited onto or integrated into the porous permeate spacer to create positive feed channels in the permeate spacer. In additional example embodiments, the material creating the channels can comprise photopolymers, hot melt polyolefins, curable polymers or adhesives, or other materials. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a top view and a side view of a variety of features printed into the interstitial space of a permeate spacer mesh and of features printed both into and on top of the mesh. 
         FIG. 2  is a cross section view of a 3D printed material in the interstitial space of a permeate spacer with conventional feed spacer between the adjacent layers. 
         FIG. 3  is a cross section view of a 3D printed material in the interstitial space and protruding above the permeate spacer which embosses the membrane sheet to form a flow channel in place of the conventional feed spacer. 
         FIG. 4  is a cross section view of a 3D printed material in the interstitial space and protruding through the permeate spacer between two sandwiched sheets of feed spacer producing a more free flow path between the adjacent permeate spacer sheets with conventional feed spacer between the adjacent layers. 
         FIG. 5  is a cross section view of a 3D printed material in the interstitial space and protruding above the permeate spacer between two sandwiched sheets of feed spacer producing a more free flow path between the adjacent permeate spacer sheets. The protrusions adjacent to the membrane sheet emboss the membrane to form a flow channel in place of the conventional feed spacer. 
         FIG. 6  is a view of flow control features deposited in to the interstitial spaces of a permeate spacer within a spiral-wound PRO membrane element. 
     
    
    
     MODES FOR CARRYING OUT THE INVENTION AND INDUSTRIAL APPLICABILITY 
     Referring initially to  FIG. 1 , a single deposited feature or plurality of deposited features  10  such as posts, islands, straight, curved, or angled line segments or continuous lines, or other complex shapes can be deposited into 16 or through and onto the surface of the permeate spacer mesh  12  or printed or otherwise applied into the interstitial spaces of the permeate spacer to create arbitrary flow paths  14  in the permeate spacer, or can be introduced into the permeate spacer during the manufacturing process of the porous permeate spacer layer. The flow channels created in the permeate spacer can also incorporate features protruding above the surface of the permeate spacer to create protrusions on top of the permeate spacer  18 . As shown in  FIG. 3 , such protrusions can be used to act to emboss  30  the surface of the membrane sheet adjacent to the permeate spacer  20  to create a separation between the membrane and spacer with the flat bottom membrane  22  of the adjacent layer. They can be used to direct flow  26  through the permeate carrier mesh and can also be used as a spacer between adjacent stacked sheets of permeate spacer to provide lower resistance to fluid flow  40  through this permeate spacer stacked layer, as shown in  FIG. 4 . Additionally a thicker two-layer permeate spacer can be produced by stacking one layer with features printed in or through and above the spacer on top of a layer of permeate spacer that has features printed through and above it to create interstitial spaces  42  to allow significantly freer flow through these spaces between the permeate spacer than flow through the permeate spacer mesh itself, as shown in  FIG. 4  and  FIG. 5 . 
     Referring to  FIG. 6 , in some designs of a spiral wound PRO element, a center tube  60  containing a flow separator  62  facilitates liquid flow from the inlet flow  68  through inlet holes  70  into the permeate spacer mesh. The printed features are used to direct and regulate flow through the permeate spacer to optimize flow and mass transfer between the liquid within the permeate spacer and the cross flow feed before the returning permeate flow returns through the outlet holes in the center tube  64  and joins the outlet flow from the center tube  66 . In cases where two layers of spacer mesh are used separated by raised features on one layer, the spaces between the layers will create pathways of low resistance to flow, and thus lower pressure drop along the pathways, while still allowing adequate flow through the permeate spacer to the membrane surface to provide adequate mass transfer. 
     In an example embodiment the deposited features are used to form arbitrary flow paths through the permeate spacer and a conventional feed spacer mesh is used to separate the adjacent layers within the spiral wound element. 
     In an example embodiment the deposited features are used to form arbitrary flow paths through the permeate spacer and the embossed features create spaces in the brine feed channel that otherwise replace feed spacer mesh material that is currently used in the art of fabricating spiral wound membrane elements. 
     In an example embodiment two layers of permeate spacer are stacked on top of one another instead of using a single layer with the deposited features forming arbitrary flow paths through the permeate spacer and the protrusions deposited on one or both layers create a space between the layers that creates significantly lower resistance to fluid flow than the permeate spacer material itself while a conventional feed spacer mesh is used to separate the adjacent layers within the spiral wound element. 
     In an example embodiment two layers of permeate spacer are stacked on top of one another instead of using a single layer with the deposited features forming arbitrary flow paths through the permeate spacer and the protrusions deposited on one or both layers create a space between the layers that creates significantly lower resistance to fluid flow than the permeate spacer material itself while the embossed features create spaces in the brine feed channel that otherwise replace feed spacer mesh material that is currently used in the art of fabricating spiral wound membrane elements. 
     The height and shape of the features can be configured to provide flow paths within the permeate spacer and spacing for embossed or protruding features appropriate to free flow in their respective flow regimes. The features do not need to be entirely solid and can contain some degree of permeability, depending on the printing materials and techniques used. Some amount of permeability can be acceptable because the patterns are made to direct flow but do not need to entirely separate flow. A small amount of flow or diffusion across the patterns that do not substantially affect bulk flow can be acceptable in some applications. 
     Those skilled in the art appreciate that the features can be comprised of various materials that are compatible with the separated fluid and the permeate spacer including, but not limited to, thermoplastics, reactive polymers, waxes, or resins. Additionally, materials that are compatible with the separated fluid but not compatible with direct deposition to the permeate spacer, including, but not limited to high-temperature thermoplastics, metals, or ceramics, can be pre-formed, cast, or cut to the proper dimensions and adhered to the surface of the permeate spacer with an adhesive that is compatible with the permeate spacer. 
     Those skilled in the art appreciate that the features can be deposited by a variety of techniques. Traditional printing techniques such as offset printing, gravure printing, and screen printing, can be suitable, although there can be thickness and geometry limitations with these deposition techniques. Thicker features can be deposited by microdispensing, inkjet printing, fused deposition, or via application using an adhesive that can include roll transfer of sheet or pick-and-place of individual features. 
     The present invention has been described in connection with various example embodiments. It will be understood that the above description is merely illustrative of the applications of the principles of the present invention, the scope of which is to be determined by the claims viewed in light of the specification. Other variants and modifications of the invention will be apparent to those skilled in the art.