Ceramic Membrane Filter Intermediate Layer Crack Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing ceramic membrane filters face challenges in increasing membrane thickness without generating defects such as tears during the drying process, which affects their performance and reliability.
Innovation Solution
A ceramic membrane filter is developed with an intermediate membrane formed using a raw material slurry containing a resin with a low molecular weight dry crack inhibitor, deflocculant, and polysaccharide compound, allowing for a thicker membrane formation with reduced defects by controlling the viscosity and drying process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the membrane formed on the substrate is increased, then the filtration capacity and structural integrity are improved, but defects such as tears are easily generated during drying
Solution Approach 1:
The patent changes the chemical composition parameters of the organic binder by specifying a molecular weight of 1000 or less and a chain structure, which fundamentally alters the drying behavior and mechanical properties of the membrane during formation, enabling thicker membranes without tears
Solution Approach 2:
The patent creates a composite organic binder system combining a low molecular weight resin with a chain structure and specific functional groups, which provides both structural support and crack resistance during the drying process
2Strength
If the thickness of the intermediate membrane is increased to suppress defect generation, then the membrane strength is improved, but the drying process becomes more difficult and defect generation increases
Solution Approach 1:
The patent modifies the physical and chemical parameters of the organic binder (molecular weight ≤1000, chain structure) to optimize the balance between membrane strength and drying ease, enabling thicker membranes to be formed without excessive drying difficulty
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 solution effectively suppresses membrane defects, enabling the formation of thicker intermediate and separation membranes with improved structural integrity and performance, including higher initial bubbling pressure and reduced crack sizes, thus enhancing filtration efficiency.
Implementation Method 1
the dry crack inhibitor in the organic binder contained in the raw material slurry has a relatively low molecular weight of 1000 or less, which can further suppress an increase in the viscosity of the raw material slurry
Implementation Method 2
tearing during drying can be suppressed by the organic binder
Data Source
AI summary
A ceramic membrane filter includes a porous substrate including cells through which a fluid flows, an intermediate membrane formed on the porous substrate, and a separation membrane formed on the intermediate membrane. In this ceramic membrane filter, the percentage of the number of cells having cracks with a size of 4 μm or less relative to the total number of cells is 9% or less.