Ceramic Base Material Porosity Balance Permeability Strength
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Solution Overview
Problem
Existing ceramic base materials for separation membranes face challenges in balancing permeability resistance and strength, as increasing porosity reduces resistance but weakens the material, while reducing porosity improves strength but increases resistance, making it difficult to achieve both simultaneously.
Innovation Solution
A ceramic base material comprising a combination of coarse and fine ceramic particles with specific size and aspect ratios, along with an inorganic binding material, is used to create a porous structure that optimizes both permeability and strength, with a porosity range of 20-50% and a coarse-to-fine particle ratio between 0.05 and 0.3, and a column-like shape with penetrating cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If porosity of the porous support is increased to reduce resistance to permeability, then resistance to permeability is reduced, but strength of the porous support is lowered
Solution Approach 1:
The invention applies local quality by creating distinct regions within the porous support with different porosity levels. A first porous layer with higher porosity (50-80%) is positioned on the feed solution side to reduce permeability resistance, while a second porous layer with lower porosity (20-40%) is positioned on the permeate side to provide mechanical strength. This spatial differentiation of porosity properties resolves the contradiction between permeability and strength.
Solution Approach 2:
The invention employs composite materials by combining two porous layers with different porosity characteristics into a single integrated support structure. The composite structure integrates the high-porosity layer (for low resistance) and the low-porosity layer (for high strength), achieving both permeability and strength requirements that cannot be met by a single uniform porous material.
2Strength
If porosity of the porous support is reduced to improve strength, then strength of the porous support is improved, but resistance to permeability is increased
Solution Approach 1:
The invention applies local quality by creating distinct regions within the porous support with different porosity levels. A first porous layer with higher porosity (50-80%) is positioned on the feed solution side to reduce permeability resistance, while a second porous layer with lower porosity (20-40%) is positioned on the permeate side to provide mechanical strength. This spatial differentiation of porosity properties resolves the contradiction between permeability and strength.
Solution Approach 2:
The invention employs composite materials by combining two porous layers with different porosity characteristics into a single integrated support structure. The composite structure integrates the high-porosity layer (for low resistance) and the low-porosity layer (for high strength), achieving both permeability and strength requirements that cannot be met by a single uniform porous material.
Data Source
AI summary
A base material utilized for supporting a separation membrane includes a plurality of coarse particles each being a ceramic particle having a particle diameter of greater than or equal to 30 μm and a plurality of fine particles each being a ceramic particle having a particle diameter of greater than or equal to 1 μm and less than 30 μm. The ratio of the number of coarse particles to the number of fine particles (i.e., coarse particle ratio) is higher than or equal to 0.05 and lower than or equal to 0.3. The coarse particles have an average aspect ratio of higher than or equal to 1.5 and lower than or equal to 2.