Membrane-integrated energy exchange assembly
View Patent ↗A method of forming a membrane panel configured to be secured within an energy exchange assembly may include forming an outer frame defining a central opening, and integrating a membrane sheet with the outer frame. The membrane sheet spans across the central opening, and is configured to transfer one or both of sensible energy or latent energy therethrough. The integrating operation may include injection-molding the outer frame to edge portions of the membrane sheet. Alternatively, the integrating operation may include laser-bonding, ultrasonically bonding, heat-sealing, or the like, the membrane sheet to the outer frame.
1. An air channel for use in an energy exchange assembly, the air channel comprising:
two membrane panels, each of which comprises:
an outer frame defining a central opening, the outer frame including a plurality of upstanding corners; and
a porous membrane sheet integrated with the outer frame, wherein the membrane sheet spans across the central opening, and wherein the membrane sheet is configured to transfer sensible energy and latent energy therethrough; and
a membrane spacer separate from and disposed between the two membrane panels, the membrane spacer comprising a connecting bracket configured to be disposed between corners of the outer frames of the two membrane panels, the connecting bracket comprising a beveled end having a distal tip that connects to a base by a sloped surface.
2. The air channel of claim 1 , wherein the outer frame is injection-molded around edge portions of the respective membrane sheet.
3. The air channel of claim 1 , wherein the membrane sheet is ultrasonically bonded to the outer frame.
4. The air channel of claim 1 , wherein the membrane sheet is laser-bonded to the outer frame.
5. The air channel of claim 1 , wherein the membrane sheet is heat-sealed to the outer frame.
6. The air channel of claim 1 , wherein the outer frame includes a plurality of brackets having inner edges that define the central opening.
7. The air channel of claim 6 , wherein one or more spacer-securing features is formed through or in at least one of the inner edges.
8. The air channel of claim 1 , wherein the outer frame includes a plurality of upstanding corners.
9. The air channel of claim 1 , wherein the membrane sheet is integrated with the outer frame without an adhesive.
10. The air channel of claim 1 , wherein the outer frame fits together with at least one separate membrane spacer to form at least one airflow channel.
11. The air channel of claim 1 , wherein the outer frame is integrally molded and formed with at least one membrane spacer.
12. An energy exchange assembly comprising:
a plurality of membrane spacers; and
a plurality of membrane panels, each of the plurality of membrane panels including:
an outer frame defining a central opening defining a fluid channel; and
a porous membrane sheet integrated with the outer frame, wherein the membrane sheet spans across the central opening, and wherein the membrane sheet is configured to transfer sensible energy and latent energy therethrough,
wherein each of the plurality of membrane spacers is separate from and positioned between two of the plurality of membrane panels, each of the plurality of membrane spacers comprising a connecting bracket configured to be disposed between corners of the outer frames of the two of the plurality of membrane panels, the connecting bracket comprising a beveled end having a distal tip that connects to a base by a sloped surface.
13. The energy exchange assembly of claim 12 , wherein the plurality of membrane panels includes a first group of membrane panels and a second group of membrane panels, wherein the first group of membrane panels is orthogonally oriented with respect to the second group of membrane panels.
14. The energy exchange assembly of claim 12 , wherein the outer frame is injection-molded around edge portions of the membrane sheet.
15. The energy exchange assembly of claim 12 , wherein the membrane sheet is one of ultrasonically bonded, laser-bonded, or heat-sealed to the outer frame.
16. The energy exchange assembly of claim 12 , wherein the outer frame includes a plurality of brackets having inner edges that define the central opening.
17. The energy exchange assembly of claim 12 , wherein one or more spacer-securing features is formed through or in at least one of the inner edges.
18. The energy exchange assembly of claim 12 , wherein the outer frame includes a plurality of upstanding corners.
19. The energy exchange assembly of claim 18 , wherein the connecting bracket of each of the plurality of membrane spacers comprises a reciprocal shape to the plurality of upstanding corners.
20. The energy exchange assembly of claim 12 , wherein the outer frame includes at least one sloped connecting bracket configured to mate with the connecting bracket of one of the plurality of spacers.
21. The energy exchange assembly of claim 12 , wherein the plurality of spacers and the plurality of membrane panels form stacked layers.
22. The energy exchange assembly of claim 12 , wherein the membrane sheet is integrated with the outer frame without an adhesive.