Carbon Membrane Core-Skin Structure for High-Pressure Separation
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Solution Overview
Problem
Conventional hollow-fiber carbon membranes are insufficient in pressure resistance, making them unsuitable for high-pressure applications such as natural-gas purification and chemical industry processes.
Innovation Solution
A carbon membrane with a core layer having a co-continuous porous structure and a skin layer with substantially no co-continuous porous structure, featuring a structural period of 0.05 to 3 µm and an area ratio of the hollow part to the carbon membrane cross-sectional area of 0.05 to 0.6, enhancing pressure resistance and fluid permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional hollow-fiber carbon membranes are used, then production cost is reduced and manufacturing simplicity is improved, but pressure resistance deteriorates
Solution Approach 1:
The membrane is divided into two distinct layers: a core layer with co-continuous porous structure for flexibility and permeability, and a skin layer with substantially no co-continuous porous structure for pressure resistance. This segmentation allows each layer to perform its specialized function, resolving the contradiction between pressure resistance and structural simplicity.
Solution Approach 2:
The invention uses a composite structure combining two different membrane types (porous carbon membrane and non-porous carbon membrane) into a single hollow fiber. The core layer provides mechanical flexibility and fluid permeability, while the skin layer provides pressure resistance, achieving high pressure resistance without excessive structural complexity.
2Productivity
If a co-continuous porous structure is formed in the core layer, then fluid permeability is improved, but structural stability under high pressure deteriorates
Solution Approach 1:
The functional segmentation separates fluid permeability functions (core layer with porous structure) from structural stability functions (skin layer with dense structure). This allows the core layer to maintain high fluid permeability through its co-continuous porous structure while the skin layer provides the structural stability needed for high-pressure operation.
Solution Approach 2:
Different regions of the membrane are given different local qualities: the core layer has a co-continuous porous structure optimized for fluid permeability, while the skin layer has a substantially non-porous structure optimized for structural stability and pressure resistance. This local differentiation resolves the contradiction between permeability and stability.
3Productivity
If the hollow part area ratio is increased, then fluid flow capacity is improved, but pressure resistance deteriorates
Solution Approach 1:
The segmentation into core and skin layers allows the hollow part area ratio to be optimized for fluid flow capacity without compromising pressure resistance. The skin layer, being dense and structurally sound, provides the pressure resistance needed to support larger hollow part area ratios that would otherwise weaken the membrane structure.
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 carbon membrane achieves excellent pressure resistance and fluid permeability, enabling its use in high-pressure conditions where conventional membranes fail, thus improving efficiency and energy savings in separation processes.
Implementation Method 1
a core layer which has a co-continuous porous structure having a structural period of 0.05 to 3 μm
Implementation Method 2
a process for producing the carbon membrane for fluid separation, the process including: a step in which a carbonizable resin and an eliminable resin are brought into a compatibly mixed state to obtain a resin mixture (step 1)
Implementation Method 3
a step in which the resin mixture in a compatibly mixed state is caused to undergo phase separation and the separated phases are fixed to obtain a precursor for the carbon membrane (step 2)
Data Source
Figure 1
AI summary
The present invention provides a carbon membrane for fluid separation with which a high-pressure fluid can be separated and purified and which has excellent pressure resistance and is less apt to be damaged. The present invention relates to a carbon membrane for fluid separation, including: a core layer which has a co-continuous porous structure; and a skin layer which has substantially no co-continuous porous structure and is formed around the core layer.