Gas Separation Membrane Master Batch Dispersion

Solution Overview

Problem

Existing gas separation membranes face challenges in achieving uniform dispersion of inorganic nanoparticles in a polymer matrix, leading to aggregation, reduced mechanical strength, and inadequate gas permeability, which impairs their performance.

Innovation Solution

A method involving the creation of a master batch by mixing silica nanoparticles with a specific polymer compound, such as PIM-1, dimethylsilicone, or poly(vinyl alcohol), and dissolving it in a solvent for application and evaporation to form a gas separation membrane, ensuring uniform dispersion and improved membrane formability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If inorganic nanoparticles are added to a polymer matrix to improve gas permeability, then gas permeability is enhanced, but the nanoparticles aggregate and membrane strength decreases

Engineering Contradiction:

Improvegas permeabilityVSAvoidmembrane strength

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The patent uses a master batch as an intermediary medium to disperse nanoparticles uniformly before final membrane formation. The master batch contains pre-dispersed nanoparticles in a polymer matrix, which are then redistributed uniformly during membrane casting, preventing aggregation and maintaining membrane strength while achieving high gas permeability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent performs preliminary dispersion of nanoparticles in the master batch preparation stage before final membrane formation. This preliminary action ensures uniform nanoparticle distribution is established early, preventing subsequent aggregation during membrane casting and maintaining both strength and permeability.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If inorganic nanoparticles are incorporated into a polymer membrane to enhance gas separation performance, then gas permeability increases, but aggregation occurs and manufacturing complexity increases

Engineering Contradiction:

Improvegas separation performanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges nanoparticle dispersion and membrane formation into a unified process using master batch. The master batch integrates nanoparticles with polymer matrix in advance, allowing subsequent membrane casting to proceed as a single homogeneous mixture, thereby simplifying manufacturing while achieving high gas separation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary dispersion of nanoparticles in the master batch preparation stage before final membrane formation. This preliminary action ensures uniform nanoparticle distribution is established early, preventing subsequent aggregation during membrane casting and maintaining both strength and permeability.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If fine particles are mixed with resin to improve membrane properties, then gas permeability is enhanced, but uniform dispersion is difficult to achieve

Engineering Contradiction:

Improvegas permeabilityVSAvoiddispersion uniformity

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent uses a master batch as an intermediary medium to disperse nanoparticles uniformly before final membrane formation. The master batch contains pre-dispersed nanoparticles in a polymer matrix, which are then redistributed uniformly during membrane casting, preventing aggregation and maintaining membrane strength while achieving high gas permeability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach allows for the production of high-performance gas separation membranes with enhanced dispersibility and gas permeability, preventing nano-cracking and warpage, and maintaining membrane integrity.

Implementation Method 1

dissolving it in a solvent for application and evaporation to form a gas separation membrane

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS11426700B2Gas separation membrane manufacturing method

Publication Date: 2022.08.30 NISSAN CHEM CORP

AI summary

A method for producing a gas separation membrane containing fine particles uniformly dispersed in a resin, including the following (A) and (B): (A) a step of mixing the fine particles with a matrix resin, the amount of the fine particles with respect to the entire mass of the mixture being adjusted to 1 mass % to 50 mass %, to thereby prepare a master batch; and (B) a step including dissolving the master batch in a solvent, applying the prepared solution onto a substrate, and evaporating the solvent.