Cordierite Membrane Monolith with Controlled Pore Size
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Solution Overview
Problem
Existing methods for creating cordierite monolith substrates with inorganic membranes face challenges in achieving small pore sizes and crack-free surfaces, which are necessary for maintaining a vacuum and ensuring the integrity of polymer-coated membranes for applications like gasoline component separation.
Innovation Solution
A method involving a two-step milling process of attrition milling followed by jet milling is used to produce cordierite particles with a median particle size of 1-4 µm, which are then applied as a slurry to the monolith substrate, followed by firing to create a membrane with a median pore size between 0.1 and 1 µm, ensuring a smooth and crack-free surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single-step milling is used to produce cordierite particles, then the manufacturing process is simple, but the resulting membrane has large pore sizes and surface defects
Solution Approach 1:
The milling process is divided into two distinct stages: attrition milling followed by jet milling. Each stage serves a specific function - attrition milling reduces particle size to a manageable range, while jet milling achieves the final fine particle size distribution needed for small pore membranes. This segmentation allows optimization of each milling stage independently, achieving precise pore size control without overwhelming complexity
Solution Approach 2:
Attrition milling is performed as a preliminary step before jet milling to reduce the cordierite particles to an intermediate size range. This preliminary action prepares the material for the subsequent jet milling stage, making the overall process more efficient and enabling the final fine particle size needed for small pore membranes
2Reliability
If conventional coating methods are used, then the manufacturing process is simple, but the membrane surface has cracks and is unsuitable for vacuum applications
Solution Approach 1:
The slurry composition parameters are carefully controlled, including solid content (3-25 wt%), viscosity, and particle size distribution. The slurry is applied at controlled conditions and fired at specific temperatures (900-1200°C) to achieve complete burnout of organic binders without causing cracks. These parameter changes ensure the membrane can withstand vacuum conditions while maintaining a smooth, crack-free surface
3Reliability
If large pore size cordierite particles are used, then the membrane has high permeability, but it cannot maintain a vacuum and supports polymer coating
Solution Approach 1:
The patent uses porous cordierite particles with carefully controlled pore sizes (0.1-1 µm) in the membrane layer. This porous structure provides the necessary vacuum holding capability while maintaining sufficient permeability for the intended application. The pore size is optimized to balance vacuum integrity with fluid transport 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 resulting cordierite membrane monolith achieves the desired small pore size and surface smoothness, enabling it to support a polymer membrane that can maintain a vacuum and perform effectively in applications such as gasoline component separation.
Implementation Method 1
a two-step milling process of attrition milling followed by jet milling is used to produce cordierite particles with a median particle size of 1-4 µm
Implementation Method 2
a two-step milling process of attrition milling followed by jet milling is used to produce cordierite particles with a median particle size of 1-4 µm
Implementation Method 3
followed by firing to create a membrane with a median pore size between 0.1 and 1 µm
Data Source
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AI summary
Described herein is a cordierite membrane coated on a monolith substrate formed from cordierite. The membrane coating is formed from cordierite particles which have been processed to have a median particle size diameter of between 1 and 3 microns with a narrow particle size distribution suitable for forming a cordierite membrane on a cordierite monolith substrate. After the cordierite membrane is formed on the cordierite monolith substrate, the cordierite membrane monolith has a pore size of less than 1 micron.