Potting method

• US 6,974,554 B2
• Filed: 09/30/2003
• Issued: 12/13/2005
• Est. Priority Date: 04/04/2001
• Status: Expired due to Fees

• Current Assignee: Evoqua Water Technologies LLC, PALL Seitzschenk Filtersystems GmbH
• Original Assignee: PALL Seitzschenk Filtersystems GmbH, US Filter Wastewater Group Incorporated (Siemens AG)
• Inventors: Cox, David John, Zha, Fufang, Lea, Cinzia, Schnieder, Georg, Muller, Joachim
• Primary Examiner(s): ORTIZ, ANGELA Y
• Application Number:
  US10/676,458
• Publication Number:
  US 20050087898A1
• Time in Patent Office: 805 Days
• Field of Search: 264/40.6, 264/255, 264/261, 264/263, 264/271.1, 264/277, 264/310, 264/311, 425/121, 425/123, 425/127, 425/425, 425/382.2, 156/296, 96/8, 96/10, 210/500.23
• US Class Current: 264/40.6
• CPC Class Codes: B01D 63/022 Encapsulating hollow fibres
• CPC Class Codes: B01D 63/0221 using a mould
• CPC Class Codes: B01D 63/0225 Multiple encapsulation layers

Abstract

A method of forming a pot for an array of hollow fiber membranes (7) is provided, including the steps of placing the ends (6) of the fiber membranes (7) in a mould (5); forming a first layer (20) of curable resin material in a non-cured state around the fiber membrane ends (6), applying a second layer (21) of a polyurethane resin material to the first layer (20) prior to full curing of the first layer, the polyurethane resin material layer being chemically reactive with the first layer material to form an adhesive bond therebetween; at least partially curing both layers and removing the pot formed from the mould (5), wherein the second layer material is of higher flexibility than the first layer material when each layer is fully cured. Apparatus for performing the method is also disclosed.

Claims

1. A method of forming a pot for an array of hollow fibre membranes, each fibre membrane comprising an end, the method comprising:

placing the ends of the fibre membranes in a mould;

forming a first layer of a curable resin material in a non-cured state around the ends, wherein the step of forming a first layer of a curable resin material further comprises monitoring a curing process of the first layer to determine an optimal time at which to apply a second layer to the first layer;

applying a second layer of a polyurethane resin material to the first layer prior to full curing of the first layer, wherein the polyurethane resin material is chemically reactive with the curable resin material to form an adhesive bond between the first layer and the second layer, and wherein a fully cured polyurethane resin material is of a higher flexibility than a fully cured curable resin material;

at least partially curing the first layer and the second layer, such that a pot is formed; and

removing the pot from the mould.

2. The method according to claim 1, wherein the curable resin material comprises an epoxy resin.

3. The method according to claim 1, wherein the first layer comprises at least one flexibilising agent.

4. The method according to claim 1, wherein the step of monitoring comprises monitoring a temperature change within the first layer to determine a state of the curing process.

5. A method of forming a pot for an array of hollow fibre membranes, each fibre membrane comprising an end, the method comprising:

placing the ends of the fibre membranes in a mold;

providing a potting sleeve within the mould to receive a first layer and a second layer, wherein the potting sleeve comprises adhesion means, wherein the adhesion means assist in adhesion of at least one of the curable resin material and the polyurethane resin material to the potting sleeve;

forming a first layer of a curable resin material in a non-cured state around the ends;

applying a second layer of a polyurethane resin material to the first layer prior to full curing of the first layer, wherein the polyurethane resin material is chemically reactive with the curable resin material to form an adhesive bond between the first layer and the second layer, and wherein a fully cured polyurethane resin material is of a higher flexibility than a fully cured curable resin material;

at least partially curing the first layer and the second layer, such that a pot is formed; and

removing the pot from the mould.

6. The method according to claim 5, wherein a surface of the potting sleeve in contact with at least one of the curable resin material and the polyurethane resin material is roughened.

7. The method according to claim 5, wherein the potting sleeve comprises at least one protrusion formed on a surface of the potting sleeve in contact with at least one of the curable resin material and the polyurethane resin material.

8. The method according to claim 5, wherein the potting sleeve comprises at least one indentation formed on a surface of the potting sleeve in contact with at least one of the curable resin material and the polyurethane resin material.

9. A method of forming a pot for an array of hollow fibre membranes, each fibre membrane comprising an end, the method comprising:

placing the ends of the fibre membranes in a mould;

forming a first layer of a curable resin material in a non-cured state around the ends, wherein the curable resin material comprises epoxy groups;

applying a second layer of a polyurethane resin material comprising amine groups or amide groups to the first layer prior to full curing of the first layer, wherein the amine groups or amide groups of the polyurethane resin material chemically react with the epoxy groups of the curable resin material to form an adhesive bond between the first layer and the second layer, and wherein a fully cured polyurethane resin material is of a higher flexibility than a fully cured curable resin material;

at least partially curing the first layer and the second layer, such that a pot is formed; and

removing the pot from the mould.

10. The method according to claim 9, wherein the first layer comprises at least one flexibilising agent.

11. The method according to claim 9, wherein the step of forming a first layer of a curable resin material further comprises monitoring a curing process of the first layer to determine an optimal time at which to apply a second layer to the first layer.

12. The method according to claim 9, further comprising the step of providing a potting sleeve within the mould to receive a first layer and a second layer, wherein the potting sleeve comprises adhesion means, wherein the adhesion means assist in adhesion of at least one of the curable resin material and the polyurethane resin material to the potting sleeve.

13. The method according to claim 9, further comprising the step of providing a potting sleeve within the mould to receive a first layer and a second layer, wherein the potting sleeve comprises at least one protrusion formed on a surface of the potting sleeve in contact with at least one of the curable resin material and the polyurethane resin material.

14. The method according to claim 9, further comprising the step of providing a potting sleeve within the mould to receive a first layer and a second layer, wherein the potting sleeve comprises at least one indentation formed on a surface of the potting sleeve in contact with at least one of the curable resin material and the polyurethane resin material.