[001] This specification relates to hollow fiber membranes and to an apparatus and method for making supporting structures for hollow fiber membranes.

BACKGROUND

[002] US Patent 6,354,444 describes an asymmetric membrane comprising a tubular polymeric film supported on a tubular braid. The braid is flexible yet strong enough to withstand flexing and stretching when the membrane is used for microfiltration (MF) or ultrafiltration (UF), The braid is prefabricated according to specified physical parameters such mat the braid has a wall thickness in the range of 0.2 mm to 1.0 mm and limited air permeability. The tubular polymeric film has a thickness of less than 0.2 mm and is formed by casting a dope on the braid while the braid is fed through a coating nozzle. Although the braid is self-supporting, the coating nozzle includes a rounding orifice to ensure that the braid is completely round before the dope is coated over it. The tubular polymeric film is supported on the outer circumferential surface of the braid without the braid being embedded in the tubular polymeric film. The coated braid travels through a coagulation tank in which the dope is converted into the polymeric film.

[003] International Publication Number WO 2010/148517 describes various methods of making non-braided textile-reinforced hollow fiber membranes. Some of the methods provide a reinforcing structure that includes filaments extending around the circumference of the membrane but without the filaments being part of a braided or woven structure. Some of the reinforcing structures also include longitudinal filaments. The reinforcing structures are embedded in the membrane wall. The membranes have a ratio of inside-to-outside diameters of 0.5 or more.

INTRODUCTION

[004] The following is intended to introduce the reader to the detailed description to follow and not to limit or define the claims.

[005] This specification describes an apparatus and method for manufacturing a supporting structure for a hollow fiber membrane. The apparatus comprises a tubular support forming device and an ultrasonic welding device. The method comprises the steps of arranging a set of filaments into a tubular supporting structure and sonically welding the ilaments together at points of intersection between the filaments.

[006] This specification describes a method and apparatus for making a hollow fiber membrane. The apparatus comprises an apparatus for making a support as described above and a coating nozzle. The method comprises the steps described above for making a support and a step of incorporating the support into a hollow fiber membrane.

[007] This specification also describes a hollow fiber membrane. The membrane comprises a polymeric wall and a tubular supporting structure. The tubular supporting structure comprises filaments that cross each other in both circumferential and radial directions. The filaments are welded together at points of intersection between them.

BRIEF DESCRIPTION OF THE DRAWINGS

[008] Figure 1 is a schematic illustration of an apparatus for making a tubular supporting structure and a supported hollow fiber membrane.

[009] Figure 2 is a schematic illustration of a portion of a braided support.

[0010] Figure 3 is a cross-sectional schematic illustration of an ultrasonic welding machine and a gathering guide, the gathering guide being part of a machine for arranging filaments into a tubular supporting structure, wherein the gathering guide is located ahead of the welding machine.

[001 1] Figure 4 is a cross-sectional view of a sonotrode head of the ultrasonic welding machine of Figure 3 taken along line 4-4 of Figure 3.

[0012] Figure 5 is a cross-sectional schematic illustration of another arrangement of an ultrasonic welding machine and gathering guide in which the welding machine is ahead of the gathering guide.

[0013] Figure 6 is a cross-sectional schematic illustration of an ultrasonic welding machine and gathering guide generally as show in Figure 3 with an optional compressed gas nozzle. [0014] Figure 7 is a cross-sectional schematic illustration of an ultrasonic welding machine and gathering guide generally as show in Figure 3 with an optional mandrel.

[0015] Figure 8 is a cross-sectional schematic illustration of an ultrasonic welding machine and gathering guide having another configuration in which the welding machine is positioned within an aperture of the gathering guide, and an optional hollow mandrel.

[0016] Figure 9 is a cross-sectional view taken along line 9-9 of Figure 8.

[0017] Figure 10 is a cross-sectional schematic illustration of an ultrasonic welding machine and gathering guide having another configuration in which part of the gathering guide functions as part of the welding machine.

DETAILED DESCRIPTION

[0018] Braid supported membranes made generally as described in US Patent 6,354,444 are used in ZeeWeed™ immersed membrane modules made by GE Water & Process Technologies. These modules are used, in particular, in membrane bioreactors (MBR). Despite vigorous agitation of the membranes in MBRs, there are essentially no incidences of fiber breakage with ZeeWeed modules. A braid with fewer filaments could still produce a sufficiently strong membrane. However, the physical parameters described in US Patent 6,354,444 are chosen, at least in part, so that the braid will be self- supporting and sufficiently dense to allow a membrane forming dope to be coated on the braid.

[0019] In this specification, the words "tubular supporting structure" (alternatively called a "support") refer to a foraminous, or at least porous, structure formed of filaments that cross each other in both circumferential and radial directions. The support might, or might not, be self-supporting but can at least be manipulated into a generally tubular shape with a longitudinal bore. The support may be, for example, a woven, braided or knit tube.

[0020] Figure 1 depicts an apparatus 10 for manufacturing a support 20 that is useful in the manufacture of hollow fiber membranes. The apparatus 10 comprises a support forming machine 12 and an ultrasonic welding machine 14. The support 20 may be, for example, a knit, woven or braided support. The support forming machine 20 may be, for example, a knitting machine, braiding machine or weaving machine. The support is made up of filaments 18 that have been arranged by the support forming machine 12. The filaments 18 may be monofilaments or multifilaments such as tows or yarns. The filaments 18 travel through the support forming machine 12 and the ultrasonic welding machine 14. The ultrasonic welding machine 14 welds the filaments 18 together at at least some points of intersection between them. Optionally, a rotating spool 16 may be provided to draw the filaments 18 through the apparatus 10. Tension applied to the support 20 by the spool 16 helps keep the support 20 round with an open longitudinal bore while the filaments 18 are welded.

[0021] Optionally, a coating nozzle 17 may be provided in line with the welding machine 14 to deposit a membrane forming dope on or around the support 20 as the support 20 is made. A coated support 21 passes from the coating nozzle 17 to a coagulation bath (not shown) to form a hollow fiber membrane suitable, for example, for microfiltration or ultrafiltration processes. The coating nozzle 17 is positioned after the ultrasonic welding machine 14 and before or after the spool 16.

[0022] Optionally, the support forming machine 12 may braid the filaments 18 into a braided support 20. For example, the filaments 18 may be braided together on a vertical or horizontal tubular braiding machine, with a vertical machine preferred. The tubular braiding machine includes a track plate with intertwining tracks and multiple bobbin carriers. The bobbin carriers carry bobbins that are loaded with the filaments 18 and travel along the tracks in either a clockwise or counter-clockwise direction. As the bobbin carriers travel along the tracks, the filaments 18 are drawn towards a gathering guide 22 (as shown for example in Figure 3). The gathering guide 22 is positioned above the center of the track plate. The gathering guide 22 receives the filaments 18 and assists in forming a braided support 20.

[0023] The speed of bobbin carrier and the speed at which the braided filaments 18 are drawn through the garnering guide 22 can determine the pattern and angle of the filaments 18 within a braided support 20. For example, a braided support 20 may have about 20 to 100 picks (crosses per inch). The cylindrical wall of the braided support 20 may have a thickness from about 0.1 mm to about 0.7 mm, preferably in the range from about 0.3 to 0.5 mm. The bore may have an inner diameter in the range from about 0.25 mm to 2.3 mm.

[0024] Figure 2 shows a portion of a tubular wall of a braided support 20 laid flat. The wall has various intersections 30 at the points where two or more filaments 18 cross each other. The tension in the filaments 18 during the braiding process may compress the filaments 18 at each intersection 30. Segments of the filaments 18 between the intersections 30 define voids 32 in the wall of the support 20. The voids 32 may be uniformly or non-uniformly shaped. The voids 32 may optionally be small enough to inhibit substantial penetration of a dope that is deposited on the braided support 20 by the coating nozzle 17. Alternatively, the voids 32 may be larger such that the filaments 18 becomes partially or completely embedded in the dope.

[0025] Figure 3 depicts a cross-sectional view of the gathering guide 22 of a tubular braiding machine and parts of an ultrasonic welding machine 14 that is positioned above, or after, the gathering guide 22. Optionally, the distance between the gathering guide 22 and the ultrasonic welding machine 14 may be variable.

[0026] The ultrasonic welding machine 14 comprises a counter tool 26 and a sonotrode 24. The braided support 20 is drawn from the gathering guide 22 to pass between opposing surfaces of the counter tool 26 and the sonotrode 24. The counter-tool 26 is fixed in place and may also be referred to as an anvil or nest. The sonic welding machine 14, and optionally an associated controller (not shown), oscillates the sonotrode 24 towards and away from the counter tool 26 with an amplitude of about 10 to 150 urn at a frequency between about 15 or 20 to 70 kHz. The oscillation of the sonotrode 24 imparts acoustic energy into the filaments 18. Preferably, the sonotrode 24 oscillates in a plane that is perpendicular to the braided support 20, for example as shown by arrow X in Figure 4. Optionally, the sonotrode 24 may oscillate in a plane that is parallel to the braided support 20.

[0027] The filaments 18 are made of, or optionally coated with or comprise, a material that is susceptible to ultrasonic welding. Acoustic energy imparted by the oscillating sonotrode 24 causes the material to temporarily transition from a solid-phase into a melt-phase. While in the melt phase, portions of the material of one filament 18 may consolidate with portions of the material of another filament 18 at some or all of the intersections 30 between the filaments 18. Portions of the filaments 18 at the intersections 30 later transitions into a consolidated solid phase such mat some or all of the intersections 30 becoming welded joints. The welded joints may increase the structural stability or strength of the support 20. Alternatively, fewer filaments 18 may be used to produce a support 20 of equal strength or stability relative to a similar support without welded filaments 18.

[0028] The compression at each intersection 30, which is caused by tension applied during the braiding process, may accentuate the effects of the acoustic energy at the intersections 30. After a given portion of the braided support 20 has passed through the ultrasonic welding machine 14, the acoustic energy no longer affects the materials of the filaments 18 and the materials of the filaments 18 transition back to the solid phase.

[0029] The apparatus 10 may operate in a continuous process. The filaments 18 are drawn under tension through the forming machine 12. The forming machine 12 assembles the filaments 18 such that the filaments 18 form the support 20 as the filaments 18 pass through the gathering guide 22. One or more materials of the filaments 18 are melted by the ultrasonic welding machine 14, which causes materials from one filament 18 to consolidate with materials from another filament 18. Optionally, the ultrasonic welding machine 14 may melt the materials of the filaments 18 prior to or while gathering the filaments 18 to form the support 20. The welded support 20 is drawn from the ultrasonic welding machine 14 and may be stored for later use. Optionally, the welded support 20 may pass directly through the coating apparatus 17 to receive a membrane dope in an additional continuous, in-line, membrane forming step.

[0030] In variations of the ultrasonic welding machine 14, the shape of the opposing surfaces of the counter tool 26 and the sonotrode 24 may be configured to alter the focus of the acoustic energy. For example, one or both of the opposing surfaces may have a raised ridge that focuses the acoustic energy towards a smaller area of the support 20. The raised ridge may also cause a localized increase in compression of the filaments 18, which may localize and accentuate the effect of the acoustic energy. In another variation, one opposing surface has a raised ridge and the other opposing surface has two laterally displaced raised ridges that receive the opposing raised ridge between them. Alternatively, the opposing surfaces may be more shaped to disperse the acoustic energy over a larger flat area.

[0031] Figure 5 shows an optional arrangement for the apparatus 10 in which the ultrasonic welding machine 14 is located before the garnering guide 22. As the filaments 18 are braided and pass over the edges 60 of the counter tool 26 and the sonotrode 24 that are closest to the forming machine 12, the acoustic energy from the oscillating sonotrode 24 is imparted into the material of the filaments 18. Optionally, edges 60 may be chamfered or radiused to assist with gathering the filaments 18 and forming the braided support 20. In mis option, the materials of the filaments 18 transition to the melt phase prior to the final positioning of the intersections 30. The filaments 18 remain in the melt phase as the filaments 18 move towards their final positions relative to each other. The filaments transition to the solid phase after the intersections 30 reach their final positions to create welded intersections 30.

[0032] Optionally, the ultrasonic welding machine 14 may have a sonotrode 24 in the form of a ring, and the filaments 18 may pass through the open center of the ring before or after they enter the gathering guide 22 and form the support 20. The filaments 18 may be pressed against the ring shaped sonotrode by a bore guide, may be pulled against the ring shaped sonotrode by tension, or may merely pass by the sonotrode.

[0033] In another option, the apparatus 10 may include a bore guide, for example as will be described below in relation to Figures 6 and 7. The bore guide may support the filaments 18 to help keep the bore of the braided support 20 open until the braided support 20 has passed through the sonic welding machine 14. A bore guide may also be used to place filaments 18 against a sonotrode or counter tool.

[0034] Figure 6 shows one option in which the bore guide is a stream of a fluid, such as gas 50 (shown by the arrow in Figure S). The stream of gas SO may be a compressed gas, preferably compressed air, which is provided by a nozzle 52. Nozzle 52 is positioned between the tubular braiding machine 12 and the sonic welding machine 14. The stream of gas 50 flows coaxially with the support 20 and into the longitudinal bore and helps keep the bore of the support 20 open. [0035] Figure 7 depicts another option in which the bore guide is a mandrel 54. The mandrel 54 may be in the form of a pin, a spring pin, a tube, a pipe, a rod, a needle or any other body that will provide structural support to help keep the bore of the support 20 open. The mandrel 54 may extend from the forming machine 12 through the gathering guide 22 so mat the filaments 18 are braided at least in part around the longitudinal axis of the mandrel 54. The mandrel 54 may also extend through the gathering guide 22 and through the sonotrode 24 to support to the braided support 20 as it travels through the sonic welding machine 14.

[0036] Figure 8 depicts another option in which the bore guide comprises a hollow mandrel 56. The hollow mandrel 56 may be used to admit a bore material 58 into the support 20. The hollow mandrel 56 may be positioned between the forming machine 12 (not shown in Figure 8) and the position of the sonotrode 24 or extend from the forming machine 12. The hollow mandrel 56 may extend through the gathering guide 22 and through the ultrasonic welding machine 14. The support 20 forms at least in part around the outer surface of the hollow mandrel 56. The bore material 58 is introduced through the hollow mandrel 56 at the line speed and becomes enclosed within the braided support 20. The bore material 58 can be any material, fluid or solid, that is desirable to have enclosed within the braided support 20 during production, for example to help form the bore of the resulting membrane or support the filaments 18, or permanently, for example to form a composite membrane. This bore material 58 may be removed during a later processing step, for example before or after coating the support 20. In the example shown in Figure 9, the bore material 58 is a hollow tube of polyvinyl acetate used to help support the filaments 18 and form the bore of the resulting membrane. The tube of polyvinyl acetate remains inside the support 20 until the dope is coagulated but is dissolved out of the membrane before the membrane is put in use.

[0037] As shown in Figure 8, the ultrasonic welding machine 14 may be positioned within an aperture 62 of the gathering guide 22. The aperture 62 is large enough to house the counter tool 26 and the sonotrode 24. Optionally, the dimensions of the aperture 62 permit placing the counter tool 26 and the sonotrode 24 in a range of different positions within the aperture 62. [0038] Figure 10 depicts another option for the apparatus 10 in which the gathering guide 22 is supported in a housing 70 by springs 72. Optionally, the gathering guide 22 may contact an inner surface 74 of the housing 70 to ensure that movement of the gathering guide 22 is coaxial with the travel direction of the braided support 20. As a further option, the gathering guide 22 may have one or more low friction surfaces 76 that contact the inner surface 74. Preferably, the gathering guide 22 has three or more spaced apart low friction surfaces 76 mat contact the inner surface 74.

[0039] As shown in Figure 10, the sonotrode 24 is positioned below the gathering guide 22 in line with the longitudinal axis of the support 20. The sonotrode 24 oscillates along the longitudinal axis of the support 20 towards and away from the lower edge of the gathering guide 22 as indicated by arrows Y. In this option, the gathering guide 22 acts as a non-fixed counter-tool. The biasing force of the springs 72 is directed towards the sonotrode 24 so that the spring 72 press against the filaments 18 as they pass through a gap 78 between the sonotrode 24 and the gathering guide 22. The resulting compression may accentuate the influence of the acoustic energy on the materials of the filaments 18. The amount of compression at the gap 78 may be adjusted by selecting appropriate springs 72 or adjusting their mounting positions. The lower edge of the gathering guide 22 is preferably chamfered or radius ed to avoid cutting the filaments 18 as they pass over it. The upper edge of the sonotrode 24 may be given a complementary shape. The filaments fly over the upper edge of the sonotrode 24 without necessarily touching it. Providing a narrow gap 78 helps reduce the possibility of tangled or stray filaments 18 in the support 20.

[0040] The methods and devices described above provide alternative means of making a support for a hollow fiber membrane or a hollow fiber membrane. In some cases, the welded support may provide improved dimensional stability or strength relative to a support of similar denier that is not welded. In some cases, welding the support may reduce the incidence of stray filaments protruding from the intended inner or outer surface of the support.

[0041] Additional useful details regarding, for example, filaments, braiding machines, coating nozzles, membrane dopes and membrane forming techniques are described in US Patent 6,354,444 and International Publication Number WO 2010/148517. US Patent 6,354,444 and International Publication Number WO 2010/148517 are incorporated herein by this reference to them.

[0042] This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention. The scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art.