Ceramic Filtration Membrane with Suspension Plasma Sprayed Active Layer
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Solution Overview
Problem
Current filtration membrane technologies, particularly ceramic membranes, face challenges in scalability, cost-effectiveness, and efficiency due to complex manufacturing processes and limited applicability in aggressive environments, while polymer membranes lack stability and selectivity in such conditions.
Innovation Solution
A filtration membrane with a porous support substrate and an active layer formed by suspension plasma spraying, featuring a network of interconnected ceramic splats and particles, providing a unique microstructure for enhanced filtration efficiency and photocatalytic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic membranes are used to improve mechanical stability and chemical resistance in aggressive environments, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs a porous ceramic active layer with controlled pore sizes (0.1-10 micrometers) formed through suspension plasma spraying. The porous structure provides both mechanical strength and filtration functionality, allowing the membrane to achieve high reliability for aggressive environments while maintaining cost-effectiveness through efficient material utilization and a streamlined manufacturing process that eliminates complex multi-step fabrication.
Solution Approach 2:
The membrane consists of a composite structure with a porous ceramic active layer deposited on a support substrate. This composite design combines the chemical resistance and mechanical stability of ceramic materials with the structural integrity of the support, achieving high reliability in aggressive environments while the single-step suspension plasma spraying process keeps manufacturing costs lower than traditional multi-step ceramic membrane fabrication methods.
2Manufacturing precision
If the active layer thickness is increased to improve pollutant removal efficiency, then purification performance is improved, but water permeability decreases
Solution Approach 1:
The patent implements local quality optimization by controlling the active layer thickness to be in the range of 1-50 micrometers, with pore sizes specifically tailored (0.1-10 micrometers) to match the target pollutant size distribution. This localized optimization of structural parameters ensures high pollutant removal efficiency for specific contaminants while maintaining adequate water permeability, rather than using a uniformly thick layer that would compromise flow rate.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the suspension plasma spraying conditions (particle size, suspension concentration, spraying distance, and number of passes) to precisely control the active layer thickness and pore structure. By varying these parameters, the membrane achieves optimal balance between pollutant removal efficiency and water permeability for different application requirements, allowing flexible optimization without sacrificing either performance metric.
3Manufacturing precision
If a dense active layer is formed to enhance selectivity, then separation precision is improved, but filtration productivity decreases
Solution Approach 1:
The patent employs a porous ceramic active layer with controlled porosity (30-70%) rather than a dense structure. The pore sizes (0.1-10 micrometers) are specifically designed to provide size-based separation for target pollutants, achieving high selectivity through physical sieving mechanisms. The interconnected pore network maintains low flow resistance, ensuring adequate filtration productivity while the controlled pore size distribution delivers the required separation precision for different contaminant types.
4Manufacturing precision
If traditional slip casting-sintering method is used to manufacture ceramic membranes, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple traditional manufacturing steps into a single suspension plasma spraying process. Instead of separate steps for slurry preparation, casting, drying, and sintering, the suspension plasma spraying technique deposits and forms the ceramic active layer in one continuous operation. This consolidation maintains manufacturing precision through controlled particle deposition and sintering while dramatically reducing process complexity and eliminating the need for multiple handling and processing stages.
Solution Approach 2:
The patent replaces the traditional mechanical slip casting-sintering system with a plasma-based deposition system. The suspension plasma spraying process uses plasma energy to melt and deposit ceramic particles directly onto the support substrate, forming the active layer without requiring mechanical casting molds, extended drying cycles, or high-temperature sintering furnaces. This substitution maintains structural precision while simplifying the manufacturing apparatus and reducing process complexity.
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 achieves high water permeability, mechanical stability, and effective pollutant removal with photocatalytic activity, enabling efficient filtration and easy cleaning, suitable for various industrial applications.
Implementation Method 1
a plasma jet is used to heat and melt particles in a suspension
Implementation Method 2
heat and melt particles in a suspension
Implementation Method 3
accelerated toward the support substrate at velocities ranging from 100 to several hundred meters per second. The molten or semi-molten particles impact the substrate
Data Source
AI summary
A filtration membrane is provided. It comprises a porous support substrate and a porous active layer on top of the support substrate, wherein the active layer is formed of a network of interconnected, randomly arranged ceramic splats with ceramic particles occupying interstices between the splats, and wherein free spaces between the particles define a network of interconnected pores extending through the thickness of the active layer. There are also provided a method of filtering a feed using the membrane and a method of manufacturing the membrane by suspension plasma spraying.