Composite Gas Separation Membrane for Functional Layer Protection
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Solution Overview
Problem
Existing gas separation membranes face issues with breakage or detachment of the gas separation functional layer during module preparation or use, leading to decreased gas permeation selectivity due to weak points in the membrane structure.
Innovation Solution
A composite membrane design comprising a gas separation functional layer with a composite compound, where the presence ratio of the functional layer is 90% to 100% on at least one surface, reinforced by a compound different from the functional layer, such as silica, phenolic resins, or urethane resins, to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the thickness of the separation functional layer is decreased to increase permeability, then the strength of the separation functional layer decreases, leading to breakage or detachment during module preparation or use
Solution Approach 1:
The patent applies composite materials by combining the gas separation functional layer with a support layer having different properties. The support layer provides mechanical strength and structural integrity, while the thin functional layer maintains high permeability. This composite structure resolves the contradiction between achieving high permeability through thin layers and maintaining sufficient strength to prevent breakage during module preparation and use.
2Use of energy by moving object
If the gas separation functional layer is placed on a support to achieve both permeability and strength, then the support only provides structural function, but sites with low strength in the functional layer may still break or detach from the support
Solution Approach 1:
The patent applies local quality by creating a composite structure where the support layer provides localized reinforcement at critical points. Rather than uniformly thickening the functional layer, the support layer is strategically positioned to provide strength exactly where needed, allowing the functional layer to remain thin for high permeability while preventing breakage and detachment at vulnerable sites.
3Use of energy by moving object
If the gas separation functional layer is made thinner to improve permeability, then gas separation selectivity may be compromised due to increased breakage and detachment
Solution Approach 1:
The patent uses composite materials to resolve the contradiction between thin layer permeability and selectivity maintenance. The support layer acts as a protective backbone that prevents breakage and detachment of the thin functional layer, ensuring that the layer remains intact and maintains its gas separation selectivity while achieving high permeability through its thin structure.
4Strength
If a composite membrane with composite compound is used to reinforce the functional layer, then structural integrity is improved, but the presence ratio of functional layer must be maintained at 90% or more to ensure permeability
Solution Approach 1:
The patent applies local quality by strategically positioning the composite compound within the membrane structure. The composite compound is incorporated in a manner that provides reinforcement and structural integrity at specific locations without uniformly reducing the functional layer presence ratio below 90%. This localized reinforcement approach maintains both high structural integrity and high permeability by ensuring the functional layer remains predominant while receiving targeted support where needed.
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 composite membrane effectively prevents damage to the functional layer while maintaining high permeability to permeating gases, enhancing the durability and selectivity of the gas separation process.
Implementation Method 1
A gas separation membrane used in the membrane separation method comprises: a gas separation functional layer whose permeability to a specific gas component (permeating gas) is higher than its permeabilities to other gas components (non-permeating gases)
Implementation Method 2
a composite membrane design comprising a gas separation functional layer with a composite compound, where the presence ratio of the functional layer is 90% to 100% on at least one surface, reinforced by a compound different from the functional layer
Data Source
AI summary
A gas separation membrane includes a composite membrane, the composite membrane including: a gas separation functional layer; and a compound having a composition different from a compound constituting the gas separation functional layer, wherein the presence ratio of the gas separation functional layer at at least one surface of the gas separation membrane is not less than 90% and less than 100%. Provided is a gas separation membrane capable of suppressing damage of the gas separation functional layer during the preparation process of a gas separation membrane module or during the use of a gas separation membrane module even when the gas separation functional layer includes a site having low strength.