Composite Membrane Adhesion via Partial Impregnation
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Solution Overview
Problem
The existing separation composite membranes face issues with insufficient adhesion between layers, leading to membrane peeling and failure in maintaining desired performance, particularly under high pressure and temperature.
Innovation Solution
A separation composite membrane with a cross-linked polymer separating layer partially impregnated into a porous support layer, having a specific pore diameter and impregnation ratio, which enhances adhesion and durability while maintaining separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separation membrane is used to achieve selective permeation and separation of gas components, then separation performance is improved, but adhesion between layers deteriorates leading to membrane peeling
Solution Approach 1:
The separating layer is partially impregnated into the pores of the porous support layer, creating a nested structure where one layer is embedded within the other. This nesting approach increases the contact area between layers and creates mechanical interlocking, thereby improving adhesion while maintaining separation performance.
Solution Approach 2:
The invention uses a composite structure combining a dense separating layer with a porous support layer. The composite material design allows each layer to fulfill its specific function - the separating layer provides selective permeation while the porous support provides mechanical strength and adhesion, resolving the contradiction between separation performance and layer adhesion.
2Productivity
If the porous support layer has larger pore diameter to improve permeability, then fluid permeability is improved, but adhesion between layers deteriorates
Solution Approach 1:
The invention applies local quality by having the separating layer partially impregnated into the porous support rather than uniformly distributed. This localized impregnation in specific pore regions maintains high permeability pathways while creating sufficient adhesion points to prevent peeling, thus resolving the contradiction between permeability and adhesion.
3Strength
If the separating layer is fully impregnated into the porous support to improve adhesion, then adhesion between layers is improved, but fluid permeability deteriorates
Solution Approach 1:
The invention applies partial action by having the separating layer partially impregnated into the porous support rather than fully impregnated. This partial impregnation provides sufficient adhesion to prevent peeling while leaving enough porous structure open to maintain high fluid permeability, thus resolving the contradiction between adhesion and permeability.
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 achieves excellent fluid permeability, separation selectivity, and high adhesion between layers, effectively preventing membrane peeling and extending its service life under high pressure and temperature conditions.
Implementation Method 1
a part of a separating layer is impregnated into pores of the support upon forming the separating layer on the porous support
Implementation Method 2
the separating layer being constituted of a polymer having cross-linked structure
Implementation Method 3
a porous layer for supporting the separating layer, the porous layer having a maximum pore diameter of 0.05 to 0.5 μm
Implementation Method 4
a separation membrane, made of a specific polymer compound, which performs in selective permeation and separation of a desired gas component
Data Source
AI summary
A separation composite membrane including: a separating layer for separating fluid components, the separating layer being constituted of a polymer having cross-linked structure, and a porous layer for supporting the separating layer, the porous layer having a maximum pore diameter of 0.05 to 0.5 μm, the separating layer being partly impregnated into the porous layer in the range of 0.1 to 30% in terms of the impregnation amount ratio (ηa) defined by Formula (A):[impregnation amount ratio (ηa){%}=impregnation depth (s)/(membrane thickness (t1) of separating layer)×100] (A).