Acidic Gas Separation Membrane Sheet Defoaming Process
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Solution Overview
Problem
Current acidic gas separation membrane sheets face challenges in achieving high yield and effective separation performance due to issues like wrinkles, adhesion failures, and poor diffusion resistance, which affect their efficiency in separating gases like CO2 and H2S.
Innovation Solution
A manufacturing method and apparatus for an acidic gas separation membrane sheet involving a hydrophilic resin composition layer sandwiched between two porous layers, utilizing a defoaming process with shear application and leaving steps to remove bubbles, and an inspection step to ensure bubble-free hydrophilic resin composition, resulting in improved adhesion and reduced wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydrophilic resin composition layer is applied to form a gel layer on porous membranes, then gas separation performance is improved, but bubbles and wrinkles are generated causing adhesion failures and reduced yield
Solution Approach 1:
The patent applies a preliminary defoaming action before the gel layer is fully formed. A defoaming agent is introduced into the hydrophilic resin composition liquid before application, and the composition is subjected to shear treatment and heating to remove bubbles in advance. This preliminary removal of bubbles prevents adhesion failures and wrinkles during the subsequent gel layer formation, thereby improving manufacturing yield while maintaining gas separation performance.
Solution Approach 2:
The patent changes physical parameters of the hydrophilic resin composition liquid, including temperature, viscosity, and shear rate, to optimize bubble removal. The composition is heated to specific temperature ranges (e.g., 20-80°C) and subjected to controlled shear treatment to facilitate bubble coalescence and removal. These parameter changes enable effective defoaming while maintaining the integrity and adhesive properties of the gel layer, resolving the contradiction between performance and yield.
2Reliability
If the gel layer is formed to enhance separation performance, then CO2 separation efficiency is improved, but adhesion failures occur due to bubbles and wrinkles
Solution Approach 1:
The patent extracts and removes bubbles from the hydrophilic resin composition liquid before application using a defoaming agent and shear treatment. By taking out bubbles in advance, the gel layer forms without air pockets that would cause adhesion failures. This extraction of harmful bubbles ensures both high separation efficiency and high-quality adhesion between the gel layer and porous membranes.
Solution Approach 2:
The patent introduces a defoaming agent as an intermediary substance that facilitates bubble removal. The defoaming agent lowers surface tension and promotes bubble coalescence and detachment from the composition liquid. This intermediary mechanism enables smooth bubble-free gel layer formation, ensuring both separation performance and adhesion quality are achieved simultaneously.
3Productivity
If manufacturing process is simplified, then productivity is improved, but separation performance deteriorates due to defects
Solution Approach 1:
The patent merges multiple functions into the hydrophilic resin composition liquid: it provides both the gel layer material for separation performance and the defoaming capability through incorporated defoaming agents. This combined composition allows simultaneous achievement of bubble-free gel layer formation and high separation performance in a single application step, improving productivity without sacrificing reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method and apparatus enable the production of acidic gas separation membrane sheets with enhanced separation performance and high yield by ensuring uniform bonding and reduced defects, leading to effective gas separation and prolonged membrane lifespan.
Implementation Method 1
it has been known to use an acidic gas separation membrane sheet having a gel layer
Implementation Method 2
utilizing a defoaming process with shear application and leaving steps to remove bubbles
Implementation Method 3
a gel layer... is described
Implementation Method 4
poor diffusion resistance
Data Source
Figure 1~2
Figure 3
Figure 4(a)~6
AI summary
A manufacturing method for an acidic gas separation membrane sheet includes: a step of preparing a hydrophilic resin composition liquid for forming a hydrophilic resin composition layer (S1); a step of removing bubbles contained in the hydrophilic resin composition liquid (S2); a step of applying the hydrophilic resin composition liquid onto a first porous layer to form an applied layer on the first porous layer (S3); and a step of laminating a second porous layer on the applied layer to form a laminated body (S4). The step of removing bubbles (S2) includes: a step of applying a shear to the hydrophilic resin composition liquid (S2a); and a step of leaving the hydrophilic resin composition liquid (S2b).