A COMPRESSION SEAL

Abstract

A potting system comprising a potting unit having an integrated compressible seal formed from the same material that the potting unit is composed of.

Claims

1. A potting system (1) comprising a potting unit (2) having a body (3) comprising a distal end (5), a middle section (6) and a proximal end (7), wherein the distal end (5) is adapted to accommodate hollow fibre membranes (10) and the proximal end (7) is adapted to engage with a header (50) of a fluid treatment system, and wherein the body (3) further comprises an integrated compressible seal (4) that is continuous with and perpendicular to the body (3), and is composed of the same material as the potting unit (2), wherein the material is an elastomer.

2. The potting system (1) according to claim 1, wherein the elastomer is selected from a polysiloxane, polyurethane, a natural rubber, nitrile rubber, polyisoprenes and fluoroelastomers.

3. The potting system (1) according to claim 2, wherein the elastomer is a polysiloxane selected from silicone, silicone rubber, silicone resin, silicone foam and silicone caulk.

4. The potting system (1) according to any one of the preceding claims, wherein the integrated compressible seal (4) is positioned at a base (9) of the body (3).

5. The potting system (1) according to any one of the preceding claims, wherein membranes (10) are potted in the distal end (5) with a potting agent that is the same material as the potting unit (2).

6. The potting system (1) according to claim 5, wherein the distal end (5) is can be any shape selected from circular, a chevron, a cross, linear, square, rectangular, triangular, hexagonal, other polygonal or circular cross-sectional shapes, an ellipse, a three-pointed star, a four-pointed star, a five-pointed star.

7. The potting system (1) according to any one of the preceding claims, wherein the potting unit (2) is a single piece.

8. The potting system (1) according to any one of the preceding claims further comprising a clamp (20).

9. The potting system (1) according to claim 8, wherein the clamp (20) comprise a first part (21) and a second part (22) configured to engage with and maintain a downward force on the integrated compressible seal (4) of the potting unit (2).

10. The potting system (1) according to claim 9, wherein the first part (21) comprises a series of spaced-apart hollows (24) which are adapted to accommodate the integrated compressible seal (4) of the potting unit (2), and wherein the second part (22) comprises a series of corresponding spaced-apart hollows (25) which are adapted to accommodate and engage with the middle section (6) of the body (3).

11. The potting system (1) according to any one of claim 9 or 10, wherein the first part (21) comprises a series of male/female connectors (26) which are adapted to engage with a corresponding series of male/female connectors (27) comprised in the second part (22).

12. The potting system (1) according to any one of claims 9 to 11, wherein the first and second parts (21,22) each have an additional fastening means (28) at an end (29) thereof.

13. The potting system (1) according to any one of claims 9 to 12, further comprising a securing means (30) adapted to engage with the clamp (20) and maintain a downward force on the integrated compressible seal (4) of the potting unit 2.

14. The potting system (1) according to any one of the preceding claims, wherein the body (2) tapers from the distal end (5) towards the proximal end (7).

15. The potting system (1) according to claim 13, when dependent on claim 12, wherein the securing means (30) engages with the fastening means (28) at the end (29) of the first (21) or second (22) parts.

16. The potting system (1) according to claim 8, wherein the clamp (20) comprises a first part adapted to engage with the body of the potting unit and a second part adapted to engage with the integrated compressive seal of the potting unit.

17. The potting system (1) according to claim 16, wherein the material of the clamp comprises a durable yet rigid material.

18. The potting system according to claim 17, wherein the material of the clamp is selected from a polypropylene, polyethylene (PE), polyethylene terephthalate copolymer (PETG) and amorphous polyethylene terephthalate (APET).

19. A fluid treatment system comprising the potting system (1) of any one of the preceding claims.

20. A Membrane Aerated Biofilm Reactor (MABR), a Membrane Supported Biofilm Reactor (MSBR), a Membrane Bioreactor (MBR), a Membrane Contactor or a Membrane Filtration Unit comprising the potting system (1) of any one of claims 1 to 18.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The invention will be more clearly understood from the following description of an embodiment thereof, given by way of example only, with reference to the accompanying drawings, in which:

[0039] FIG. 1 illustrates a perspective view of one embodiment of a potting unit of the claimed invention.

[0040] FIG. 2A illustrates a first part of a two-part clamp and FIG. 2B illustrates a second part of the two-part clamp of the claimed invention, in which the clamp is configured to engage with and secure the potting unit of FIG. 1 to a header or manifold.

[0041] FIG. 3 illustrates an end part adapted to engage with the clamp shown in FIGS. 2A and 2B.

[0042] FIG. 4 illustrates the potting unit of FIG. 1 engaged with the two-part clamp of FIGS. 2a, 2b and 3, and forming the potting system of the claimed invention, wherein the potting system is attached to a header of a treatment tank.

DETAILED DESCRIPTION OF THE DRAWINGS

[0043] The invention described herein provides a potting system for use in the manufacture of a fluid treatment system, such as a MABR or MSBR, Membrane Bioreactors (MBRs, which are used for wastewater treatment), Membrane Contactors for gas delivery or gas removal (typically found in the beverage industry or chemical industry), and Membrane Filtration Units (which can be used in the chemical, pharmaceutical, or food and beverage industry), the system comprising a potting unit and, optionally, a clamp. The potting unit is typically a single piece composed of a potting agent, the same potting agent that is used to secure a bunch of hollow fibre membranes to a potting unit. The potting unit also comprise an integrated compressible seal that is resistant to attack from chemicals or other reagents that may be found within the liquid being treated and also provides a mechanical seal within the treatment system to ensure that liquid either side of the membranes do not mix.

[0044] Turning now to the Figures, wherein FIG. 1 illustrates a general embodiment of a potting system of the present invention. Specifically, FIG. 1 illustrates a perspective view of a potting unit of the potting system of the present invention, with hollow fibre membranes in place, and is generally referred to by reference numeral 1. The potting system 1 comprises a potting unit 2 having a body 3 with an integrated compressible seal 4. The body 3 comprises a distal end 5, a middle section 6, a base 9 and a proximal end 7. The integrated compressible seal 4 is continuous with the middle section 6 of the potting unit 2 and is located towards or at the base 9 of the potting unit 2.

[0045] The distal end 5 is adapted to accommodate a bunch of hollow fibre membranes 10, which are potted into the potting unit 2 using a potting agent. The potting unit 2 is typically a continuous piece made from the same potting agent used to secure the hollow fibre membranes 10 in the distal end 5 of the potting unit 2. The potting agent also creates the shape of the integrated compressible seal 4. The distal end 5 around the membranes 10 can acts as a connector that can be shaped in a particular manner (a shaped connector) to space out the membranes 10 to form unique shapes or patterns, such as that described in EP3297749. Alternatively, the distal end 5 can be cylindrical in nature.

[0046] In addition, the integrated compressible seal 4 can also be manufactured to any shape that is desired, such as circular, a chevron, a cross, linear, square, rectangular, triangular, hexagonal, other polygonal or circular cross-sectional shapes, an ellipse, a three-pointed star, a four-pointed star, a five-pointed star, and the like.

[0047] The proximal end 7 typically has connectors 8 that are configured to engage with a header 50 (see FIG. 4) of a manifold.

[0048] FIG. 2A shows a first part 21 of a two-part mechanical clamp 20, while FIG. 2B shows a second part 22 of the two-part mechanical clamp 20. The clamp 20 is adapted to encase the integrated compressible seal 4 when the potting unit 2 is engaged with the header 50 (see FIG. 4) of a manifold. The first part 21 comprises a series of spaced-apart hollows 24 which are adapted to accommodate the integrated seal 4 of the potting unit 2, and a series of male/female connectors 26 which are adapted to engage with a corresponding series of male/female connectors 27 of the second part 22. The second part 22 also comprises a series of corresponding spaced-apart hollows 25 which are adapted to accommodate the middle section 6 of the body 3. The clamp 20, when in use, can be used with any fastening means and is configured to maintain a downward force onto the integrated compressible seal 4 of the potting unit 2. The male/female connectors 26,27 typically are snap-fit connectors, however, other well-known and equally practical male/female fastening means can also be used, such as a nut and bolt arrangement, a cable tie arrangement, a coupling, a hook, a latch, a lock, a lug, a rivet and a screw. The first part 21 and second part 22 each have an additional fastening means 28 at either end 29 thereof, which is adapted to engage with a securing means 30 (see FIG. 3). The securing means 30 is adapted to lock the two-part clamp 20 in place and maintain a downward force onto the integrated compressible seal 4 of the potting unit 2. The clamp 20 can provide additional downward force at the end of a cassette of a module reactor and ensure that there is a uniform downward force along the length of the clamp 20.

[0049] FIG. 4: is an image of the potting system 1 when in use and attached to the header 50 of a module reactor. When in use, the inside of the hollow fibre membranes 10 is in fluid communication with a central channel 52 of the header 50. The header 50 is used to convey the fluid on the inside of the hollow fibre membranes 10 to or from the membranes 10. A treatment module would comprise an upper and lower header 50. The upper and lower headers 50 are connected through a manifold or piping system. The headers 50 maintain the separation of the two fluids in the module reactors.

[0050] Membranes used in the MABR are in most cases dense membranes. These membranes do not have pores but instead allow the diffusion of gas molecules through their the inter polymeric lattice. The most common materials used are Poly DiMethyl Siloxane (Silicone) or Poly Methyl Pentane. Silicone is often used in non-stick applications due to its low surface energy as well as being used in seals and gaskets due it being elastic and compressible, which can be stretched around a nozzle or nipple and compressed between two surfaces.

[0051] Because of silicone's properties it is not always easy to bond to other materials and therefore silicone is often used as the potting agent for silicone membrane because silicone will adhere to itself and it can be chemically bonded to each membrane. Most other potting agents are not compressible once solidified and therefore are not suitable for forming a mechanical seal as set out by the claimed invention. By forming the potting silicone around the membranes in such a manner as to have an integrated seal, mechanical clamps can then be used to keep the potted membranes attached to a header. By forming the potting in such a shape, the potting material can have a compression seal and thus avoids the requirement to bond the potted membranes to a header to ensure complete separation of the fluids on either side of the membrane. The compressive force used on the mechanical seal should be enough to keep the potted membranes in place, but not excessive as to damage the potting silicone and cause tears in the potting silicone. The elastomer used for potting the membranes should be of a similar bond length and use a similar same catalytic cross-linking procedure as that used for forming the hollow fibre membranes to ensure chemical compatibility. The elastomer used for forming the potting should also have the same shore hardness as the polymer used to produce the membranes.

[0052] In the specification the terms “comprise, comprises, comprised and comprising” or any variation thereof and the terms “include, includes, included and including” or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation and vice versa.

[0053] The invention is not limited to the embodiments hereinbefore described but may be varied in both construction and detail.