Three-dimensional feed spacers with tpms architectures for membrane-based systems

Abstract

A filter element comprises a membrane layer; and a feed spacer on the membrane layer, wherein the feed spacer comprises a plurality of unit cells arranged in three dimensions, wherein each of the plurality of unit cells comprises a cavity defined by a triply periodic minimal surface, and wherein the cavities of the plurality of unit cells are interconnected to allow a fluid to pass through the cavities of the plurality of unit cells.

That which is claimed is: 
     
         1 . A filter element comprising:
 a membrane layer; and   a feed spacer on the membrane layer, wherein the feed spacer comprises a plurality of unit cells arranged in three dimensions,   wherein each of the plurality of unit cells comprises a cavity defined by a triply periodic minimal surface, and   wherein the cavities of the plurality of unit cells are interconnected to allow a fluid to pass through the cavities of the plurality of unit cells.   
     
     
         2 . The filter element of  claim 1 , further comprising a permeate-side spacer defining a permeate channel on the membrane layer opposite the feed spacer. 
     
     
         3 . The filter element of  claim 2 , wherein the feed spacer defines at least a portion of a feed stream channel configured to receive a feed fluid with a solute, and wherein the membrane layer is configured to filter the feed fluid to form a permeate having a reduced concentration of the solute in the permeate channel 
     
     
         4 . The filter element of  claim 3 , wherein the feed stream channel outputs a reject stream having a higher concentration of solute than the feed stream. 
     
     
         5 . The filter element of  claim 1 , wherein the feed spacer comprises a generally planar body having opposing surfaces. 
     
     
         6 . The filter element of  claim 5 , wherein the opposing surfaces of the generally planar body define triply periodic minimal surfaces that define cavities of the plurality of unit cells. 
     
     
         7 . The filter element of  claim 5 , wherein the generally planar body is formed as a single, unitary member. 
     
     
         8 . The filter element of  claim 1 , wherein the triply periodic minimal surface is a Schwarz Primitive surface, a Schwarz crossed layers of parallels (CLP), a Schoen's Gyroid surface, a Schoen's I-WP surface, a Schwarz diamond surface, a Fischer-Koch PMY surface, a FRD surface, a Fischer-Koch CY surface, a Fischer-Koch S surface, or a Neovius surface. 
     
     
         9 . The filter element of  claim 1 , wherein the feed spacer comprises a polymeric material, a ceramics material, a metal material or composites thereof 
     
     
         10 . A filtration device comprising:
 a housing;   a filter element in the housing, the filter element comprising:
 a membrane layer; and 
 a feed stream channel defined by a feed spacer on the membrane layer, the feed stream channel being configured to receive a feed fluid therein, the feed fluid comprising a solute; and 
 a permeate-side spacer defining a permeate channel on the membrane layer opposite the feed spacer and configured to receive a permeate fluid via the membrane, the permeate fluid having a concentration of the solute that is less than a concentration of the solute in the feed fluid; 
 wherein the feed spacer comprises a plurality of unit cells arranged in three dimensions, and each of the plurality of unit cells of the feed spacer comprises a cavity defined by a triply periodic minimal surface, and wherein the cavities of the plurality of unit cells are interconnected to allow the feed fluid to pass through the cavities of the plurality of unit cells; 
   a feed channel inlet configured to provide a feed fluid input to the feed stream channel; and   a permeate outlet configured to provide a permeate output from the permeate-side spacer.   
     
     
         11 . The filtration device of  claim 10 , wherein the filter element comprises a plurality of filter elements spirally wound around a hollow tubular member, the hollow tubular member having at least one open end and apertures along a length thereof configured to receive the permeate fluid from the permeate-side spacer, and wherein the permeate outlet comprises the at least one open end of the tubular member. 
     
     
         12 . The filtration device of  claim 10 , wherein the feed stream channel is configured to output a reject stream having a higher concentration of the solute than the feed fluid. 
     
     
         13 . The filtration device of  claim 10 , wherein the housing is configured to contain fluid in the filter element under a pressure greater than atmospheric pressure. 
     
     
         14 . The filtration device of  claim 10 , wherein the feed spacer comprises a generally planar body having opposing surfaces. 
     
     
         15 . The filtration device of  claim 14 , wherein the opposing surfaces of the generally planar body define triply periodic minimal surfaces that define cavities of the plurality of unit cells. 
     
     
         16 . The filtration device of  claim 14 , wherein the generally planar body is formed of a single, unitary member. 
     
     
         17 . The filtration device of  claim 10 , wherein the triply periodic minimal surface is a Schwarz Primitive surface, a Schwarz crossed layers of parallels (CLP), a Schoen's Gyroid surface, a Schoen's I-WP surface, a Schwarz diamond surface, a Fischer-Koch PMY surface, a FRD surface, a Fischer-Koch CY surface, a Fischer-Koch S surface, or a Neovius surface. 
     
     
         18 . The filtration device of  claim 10 , wherein the feed spacer comprises a polymeric material, a ceramics material, a metal material or composites thereof. 
     
     
         19 . A feed spacer structure for a membrane-based filtration system, the feed spacer structure comprising:
 a plurality of unit cells arranged in three dimensions,   wherein each of the plurality of unit cells comprises a cavity defined by a triply periodic minimal surface, and   wherein the cavities of the plurality of unit cells are interconnected to allow a fluid to pass through the cavities of the plurality of unit cells.   
     
     
         20 . The feed spacer structure of  claim 19 , wherein the feed spacer comprises a generally planar body having opposing surfaces. 
     
     
         21 . The feed spacer structure of  claim 20 , wherein the opposing surfaces of the generally planar body define triply periodic minimal surfaces that define cavities of the plurality of unit cells. 
     
     
         22 . The feed spacer structure of  claim 21 , wherein the generally planar body is formed as a single, unitary member. 
     
     
         23 . The feed spacer structure of  claim 19 , wherein the triply periodic minimal surface is a Schwarz Primitive surface, a Schwarz crossed layers of parallels (CLP), a Schoen's Gyroid surface, a Schoen's I-WP surface, a Schwarz diamond surface, a Fischer-Koch PMY surface, a FRD surface, a Fischer-Koch CY surface, a Fischer-Koch S surface, or a Neovius surface. 
     
     
         24 . The feed spacer structure of  claim 19 , wherein the feed spacer comprises a polymeric material, a ceramics material, a metal material or composites thereof.