Carbon Membrane Silicon Gradient Defect Suppression
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Solution Overview
Problem
Conventional carbon membranes for fluid separation are prone to defects such as pinholes and cracks under high pressure conditions due to stress from expansion and contraction, and poor interfacial affinity between the hollow fiber membrane and the separation membrane, which compromises their separation and purification performance.
Innovation Solution
A carbon membrane with a dense carbon layer formed on a porous carbon support, where the silicon atom content is unevenly distributed, with a higher ratio near the interface between the support and the dense carbon layer, to enhance interfacial affinity and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dense carbon layer is formed on a porous carbon support to improve separation performance, then separation performance and permeation performance are improved, but defects such as pinholes and cracks easily occur under high pressure conditions due to stress from expansion and contraction
Solution Approach 1:
The patent applies local quality by creating a gradient distribution of silicon atoms within the porous carbon support structure. The support contains a first region with a first silicon atom content and a second region with a second silicon atom content that is higher than the first. This non-uniform distribution allows different regions to have different properties: the first region provides structural integrity while the second region with higher silicon content reduces thermal expansion and contracts less, thereby reducing stress on the dense carbon layer and preventing defect formation under high pressure conditions.
2Ease of manufacture
If the porous carbon support undergoes expansion and contraction during production and separation processes, then the membrane structure is formed, but stress is generated that causes defects in the support or carbon membrane
Solution Approach 1:
The patent applies parameter changes by modifying the silicon atom content distribution within the porous carbon support. By controlling the silicon atom content to be higher in the second region compared to the first region, the thermal and mechanical parameters of the support are optimized. The higher silicon content region has reduced expansion and contraction characteristics, which changes the stress distribution parameters during membrane formation and separation processes, preventing structural damage while maintaining manufacturability.
3Productivity
If conventional carbon supports are used, then the membrane can be produced, but the supports fuse together during production and then peel apart, generating defects
Solution Approach 1:
The patent applies the intermediary principle by introducing silicon atoms as a mediating element between the carbon structures in the porous support. The silicon atoms, particularly in the second region with higher concentration, act as a buffer that prevents direct contact and fusion between carbon support structures during high-temperature production processes. This intermediary silicon layer eliminates the peeling defect mechanism while maintaining production efficiency, as the silicon content can be controlled during standard manufacturing processes.
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 uneven distribution of silicon atoms improves the wettability and adhesion between the support and the dense carbon layer, suppressing defects and enhancing the membrane's durability and separation performance under high pressure conditions.
Implementation Method 1
The uneven distribution of silicon atoms improves the wettability and adhesion between the support and the dense carbon layer
Implementation Method 2
the carbon membrane has a molecular sieving effect of separability depending on the molecular size of the separation target
Data Source
AI summary
An object of the present invention is to suppress a defect in a carbon membrane for fluid separation use with a dense carbon layer formed on a porous carbon support. The present invention is a carbon membrane for fluid separation use, including a dense carbon layer formed on a porous carbon support, wherein X<Y when the ratio of the content of silicon atoms to the total content of carbon atoms and silicon atoms at the center position in the membrane thickness direction of the porous carbon support is X (atomic %), and the ratio of the content of silicon atoms to the total content of carbon atoms and silicon atoms at the position of 3 μm from the interface between the porous carbon support and the dense carbon layer to the porous carbon support side is Y (atomic %).