CO2 Gas Separation Membrane With Pore-Anchored Polymer Layer
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Solution Overview
Problem
Existing gas separation membranes face challenges in achieving sufficient carbon dioxide gas permeability and adhesion of the separation layer, particularly when using non-metallic materials like polymers, which can lead to poor adhesion between the separation layer and the porous substrate.
Innovation Solution
A gas separation membrane design featuring a porous body with a polymer separation layer that penetrates into its pores, with a specific thickness ratio (B/A) of 30% or more, combined with a manufacturing process involving energy application and selective removal of uncured portions to enhance adhesion and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-metallic material such as an organic material is used for the separation layer, then adhesion between the separation layer and the porous substrate may not be sufficiently increased, but carbon dioxide gas permeability is improved
Solution Approach 1:
The separation layer is formed to penetrate into the pores of the porous substrate, creating a nested structure where the separation layer is embedded within the porous body. This nesting increases the interfacial contact area between the separation layer and substrate, thereby improving adhesion while maintaining the permeability benefits of the porous structure.
Solution Approach 2:
The invention utilizes a porous substrate with controlled pore structure and combines it with a separation layer that penetrates these pores. The porous structure allows gas molecules to pass through while the penetration of the separation layer into the pores creates anchoring points that enhance adhesion, thus resolving the contradiction between adhesion strength and gas permeability.
2Reliability
If a metal coating film is formed in the small pores of the porous substrate by a plating method, then adhesion is improved, but carbon dioxide gas permeability is insufficient
Solution Approach 1:
The invention replaces the metal coating film (which provides good adhesion but blocks gas permeability) with an organic separation layer material that has sufficient adhesion properties and maintains gas permeability. The organic material acts as a shorter-lived, less aggressive alternative to metal plating, achieving both adhesion and permeability requirements.
Solution Approach 2:
The invention creates a composite structure combining a porous substrate with an organic separation layer that penetrates the pores. This composite material approach allows the system to exhibit both the adhesion properties of the organic layer and the permeability characteristics of the porous structure, overcoming the limitations of using metal coatings alone.
3Reliability
If the separation layer penetrates deeper into the pores, then adhesion is improved, but the thickness of the separation layer is reduced
Solution Approach 1:
Instead of increasing adhesion by making the separation layer thicker in one dimension, the invention transitions to a three-dimensional penetration approach where the separation layer extends into the pore depth dimension. This dimensional change allows adhesion to be improved through increased surface contact area within the pores while maintaining or reducing the overall thickness of the separation layer.
Solution Approach 2:
The separation layer exhibits different properties at different locations: at the surface it provides selective permeability, while at the penetration interfaces within the pores it provides adhesion through anchoring. This local differentiation of function allows the thin separation layer to simultaneously achieve both permeability and adhesion requirements.
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 carbon dioxide gas permeability and excellent adhesion, reducing energy input requirements and maintaining a high selectivity ratio for carbon dioxide separation.
Implementation Method 1
a separation layer provided on the first main surface and formed of a polymer material. A portion of the separation layer penetrates the pores from the first main surface
Implementation Method 2
performing a treatment of applying energy to the coating film from a side opposite to the porous body to cure or solidify the coating film
Data Source
Figure 1~2
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Figure 6~7
AI summary
A gas separation membrane for selectively permeating and separating carbon dioxide from a mixed gas containing the carbon dioxide includes: a sheet-shaped porous body having a first main surface and a second main surface which are in a front-and-rear relationship with each other, and pores connecting the first main surface and the second main surface; and a separation layer provided on the first main surface and formed of a polymer material. A portion of the separation layer penetrates the pores from the first main surface. A ratio B/A is 30% or more, where A is an average thickness of the separation layer, and B is a penetration depth of the separation layer into the porous body.