Atomically Thin Membrane Pore Formation via Substrate Islands
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Solution Overview
Problem
Current membrane technologies face challenges in maximizing flux while maintaining high selectivity, particularly in liquid-phase and gas-phase separations, due to limitations in chemical resistance and fouling control, which hinders applications in chemical separations and filtration processes.
Innovation Solution
The development of atomically thin layers, such as graphene, with controllably sized and positioned pores, formed through methods like growing on substrates with islands or by introducing defects that are selectively etched, to create membranes with enhanced selectivity and permeance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional membrane materials (polymeric or ceramic) are used, then chemical resistance is limited, but if atomically thin layers are used, then selectivity and flux are enhanced
Solution Approach 1:
The patent employs atomically thin layers (such as graphene or other 2D materials) as the active membrane layer. These ultrathin films provide exceptional selectivity and flux while maintaining chemical resistance through their inherent material properties, resolving the contradiction between conventional materials' limitations and advanced materials' capabilities.
Solution Approach 2:
The invention creates a composite membrane structure combining atomically thin active layers with support substrates. This composite approach integrates the high selectivity and flux of 2D materials with the mechanical strength and chemical stability of support structures, achieving both enhanced productivity and reliability simultaneously.
2Productivity
If increased flux rate is achieved, then permeance improves, but selectivity decreases
Solution Approach 1:
The patent introduces pores with precisely controlled sizes and positions within the atomically thin layer. By locally engineering pore characteristics (size, distribution, shape) rather than using uniform structures, the membrane achieves high flux through optimized transport pathways while maintaining selectivity through precise molecular sieving at each pore location.
Solution Approach 2:
The invention utilizes porous atomically thin layers where the pore structure is carefully engineered. The porous configuration enables high flux through interconnected transport channels while the atomic-scale precision of the 2D material walls maintains exceptional selectivity, resolving the typical flux-selectivity tradeoff.
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
These membranes achieve high selectivity and permeance by allowing controlled transport of molecules, improving filtration efficiency in applications like water purification, gas separation, and chemical separations while reducing fouling and increasing durability.
Implementation Method 1
growing an atomically thin layer on a portion of the substrate comprising the first material
Implementation Method 2
defects in the atomically thin layer are formed during growth of the at least one atomically thin active layer and/or etched during cooling from the first temperature to the second temperature
Implementation Method 3
allowing controlled transport of molecules, improving filtration efficiency
Data Source
AI summary
Atomically thin layers including pores, their method of manufacture, and their use are disclosed. In some embodiments, pores may be formed in an atomically thin layer by growing the atomically thin layer on exposed portions of a substrate that includes islands comprising a material that is different than the material of the substrate. In some embodiments, pores and/or defects may be formed in an atomically thin layer by employing growth conditions that promote the formation of defects and/or pores. In certain embodiments, pores and/or defects may be etched to enlarge their size.