Composite Gas Separator With Optimized Support Surface
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Solution Overview
Problem
Conventional gas separation separators face limitations in achieving both high mechanical strength and gas permeability due to defects in the selective layer, such as pinholes, which reduce selectivity and process stability, especially when the support's surface roughness and pore diameter are not optimized.
Innovation Solution
A composite separator with a porous polyethylene film support having a surface roughness of 100 nm or less, a median pore diameter of 300 nm or less, and a tensile strength of 10 MPa or more, allowing for a uniformly formed thin selective layer without defects, enhancing selectivity and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the support's surface roughness and pore diameter are not optimized, then the mechanical strength may be sufficient, but the selective layer forms defects such as pinholes, reducing selectivity and process stability
Solution Approach 1:
The patent optimizes specific parameters of the support structure including surface roughness (Ra ≤ 100 nm), pore diameter (50-300 nm), and tensile strength (≥10 MPa) to enable uniform selective layer formation without defects while maintaining mechanical integrity
Solution Approach 2:
The support is designed with specific local surface properties (roughness and pore distribution) that differ from the bulk material properties, creating optimal conditions for selective layer formation at the surface while maintaining overall mechanical strength
2Productivity
If a thin selective layer is formed to improve permeability, then gas permeability increases, but the layer becomes more prone to defects and reduced selectivity
Solution Approach 1:
The support surface parameters (roughness Ra ≤ 100 nm, pore diameter 50-300 nm) are optimized to enable formation of thin selective layers (10-500 nm) that maintain both high permeability and selectivity by preventing defect formation
Solution Approach 2:
The patent uses a thin selective layer that would normally be prone to defects, but compensates by using a specially engineered support that protects it and enables it to function reliably at thin dimensions
3Volume of moving object
If the support thickness is reduced to improve flexibility and reduce volume, then mechanical strength decreases, but high strength is needed to support the selective layer
Solution Approach 1:
The support is designed with optimized pore structure (50-300 nm diameter) and surface properties that enable thin film formation (5-100 μm thickness) while maintaining tensile strength of at least 10 MPa through enhanced surface mechanics
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 separator achieves significantly improved selectivity and permeability, along with increased process stability and separation efficiency, by ensuring the support's surface properties facilitate uniform selective layer formation and high mechanical strength, even at small thicknesses.
Implementation Method 1
a support and a selective layer disposed on one surface of the support, wherein the support includes a porous polyethylene film
Implementation Method 2
a composite separator for gas separation having a uniformly formed selective layer of a thin film to have significantly improved selectivity and permeability
Data Source
AI summary
Provided is a composite separator for gas separation. According to an aspect of the present disclosure, a composite separator for gas separation includes a support and a selective layer disposed on one surface of the support, wherein the support includes a porous polyethylene film, and has a surface roughness of 100 nm or less, a surface median pore diameter of 300 nm or less, and a tensile strength in a machine direction (MD) and a transverse direction (TD) of 10 MPa or more.