Abstract:
An apparatus for manufacturing membranes is provided, the apparatus comprises a casting section, a processing section and a conveyor system. The casting section prepares a membrane that is conveyed to the processing section. The conveyor system conveys the membrane through the processing section. In the processing section, the membrane is conditioned in tanks to extract residues. The membrane is also subjected to a leak test to detect physical flaws in the membrane. The leak test involves applying a dye to a surface of the membrane. Any dye that leaks through the membrane will provide a high contrast dye mark on an adjacent contrast material, which is indicative of a physical flaw in the membrane. A process for manufacturing and testing membranes is also provided. The process comprises the steps of casting a membrane precursor, curing the membrane precursor to form a membrane and processing the membrane.
Abstract:
A membrane, for example an ion exchange membrane, is made by preparing a curable liquid using at least one aqueous solvent. The curable liquid is continuously cast onto a substrate to form a membrane precursor. The membrane precursor is continuously cured to form a membrane. Optionally, the curable liquid may be made by mixing a water soluble aliphatic sulfonic acid monomer with a pair of crosslinking monomers and a water soluble free-radical generating catalyst. Optionally, the method may include one or more steps of processing the membrane.
Abstract:
A spacer for a membrane stack has an upper surface and a lower surface. The upper surface has a raised perimeter surrounding a membrane supporting section. The spacer has one or more protrusions and recesses configured such that the one or more protrusions of a first spacer fit into one or more recesses of a second spacer with the same protrusions and recesses stacked against the first spacer. Optionally, there may be an interference or snap fit. In a stack, membranes are placed on the membrane supporting sections located between spacers. In one embodiment, the bottom of an upper spacer rests on the raised perimeter of a lower spacer. A spacer may have a hole extending from an edge of the spacer to the interior of a flow field within the spacer. The hole allows access to the flow field for diagnostic testing and/or sampling.
Abstract:
A membrane stack may be used, for example, in an electrodialysis or other electrically driven membrane separation device. The stack has a plurality of modules, each containing a number of membranes and spacers bundled together. A module can be removed from the stack, for example for diagnosis or repair by sliding the module out of the stack in a direction parallel to the plane of a membrane or spacer in the stack. A banding mechanism is described for compressing a stack but can be released to allow the stack to be dis-assembled. The banding mechanism is also capable of lifting at least an upper end plate or electrode from the stack. Ports communicate with parts of a stack and may be used to perform diagnostic tests. In an embodiment, the stack has at least two modules as described above and each of the two modules has at least one port.