Dense Carbon Separation Membrane with Embedded Particles
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Solution Overview
Problem
Separation membranes with dense carbon layers suffer from defects such as pinholes and cracks due to foreign matters and pressure fluctuations, leading to reduced gas separation performance when these defects are larger than the gas molecules, causing leakage and decreased separation efficiency.
Innovation Solution
A separation membrane with a dense carbon layer that has recesses on its surface, where particles adhere and are embedded, effectively blocking defects and maintaining high separation performance even with defects present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dense carbon layer is used for separation, then separation performance is improved, but defects such as pinholes and cracks occur leading to gas leakage
Solution Approach 1:
The patent applies preliminary action by forming recesses in the dense carbon layer before the membrane is put into service. These recesses are pre-positioned to accommodate particles that will later block defects. This advance preparation ensures that when defects occur during operation, the particles can immediately fill and seal them, maintaining membrane integrity without compromising the high separation performance provided by the dense carbon structure.
Solution Approach 2:
The patent introduces particles as an intermediary element between the dense carbon layer and the defects. These particles serve as mediators that physically block the pinholes and cracks, preventing gas leakage while allowing the dense carbon layer to maintain its separation function. The particles act as a bridge that resolves the contradiction between maintaining dense structure for separation and accommodating defects that compromise integrity.
2Productivity
If high pressure is applied to increase permeation rate, then productivity is improved, but stress and defects in the membrane increase
Solution Approach 1:
The patent applies beforehand cushioning by incorporating particles into recesses that are strategically positioned to cushion against the stress and defects caused by high pressure operation. When high pressure is applied to increase permeation rate, these pre-positioned particles absorb and distribute the mechanical stress, preventing defect propagation and maintaining membrane stability throughout the high-pressure separation process.
3Productivity
If continuous operation is performed, then productivity is maintained, but new defects such as cracks occur due to vibrations and pressure fluctuations
Solution Approach 1:
The patent applies self-service by designing a system where particles in recesses automatically block new defects as they form during continuous operation. When vibrations and pressure fluctuations create new cracks or pinholes, the particles readily migrate to and seal these defects, enabling the membrane to self-repair and maintain reliability during continuous high-productivity operation without external intervention.
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 membrane maintains stable high separation performance by embedding particles in recesses of the dense carbon layer, preventing gas leakage and enhancing the membrane's ability to handle defects and pressure fluctuations.
Implementation Method 1
a separation layer containing carbon has a molecular sieve effect of separating the target substance by the molecular size
Implementation Method 2
particles adhere to a surface of the dense carbon layer, a dense layer carbon layer has a recess, and at least part of the particles are embedded in the recess
Data Source
AI summary
Stable maintenance of high separation performance of a separation membrane having a separation layer comprising a compact carbon layer is described in addition to a separation membrane having a separation layer comprising a compact carbon layer, wherein particles are attached to the compact carbon layer, recesses are present in the compact carbon layer, and the particles are at least partially stuck in the recesses.