Gas Separation Membrane with Polymer Gel Layer
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Solution Overview
Problem
Existing methods for producing gas separation membranes with inorganic porous supports face challenges in achieving thin, dense selective separation layers due to issues like pore infiltration and mechanical/thermal stress, particularly when using large-pore supports, which affects permeance and selectivity.
Innovation Solution
A method involving a polymer solution that can be physically gelled by cooling is used, where the solution is applied to a cooled inorganic porous carrier, forming a polymer gel layer that prevents infiltration and is then dried to create a thin, dense selective separation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin selective separation layer is applied to maximize permeance, then gas flux increases, but the layer becomes insufficiently dense and selective
Solution Approach 1:
The patent changes the physical state parameter of the polymer coating from direct solid deposition to solution-based coating followed by controlled drying. By adjusting solvent composition (mixing non-solvent and solvent), temperature, and drying conditions, the process achieves optimal layer density and thickness simultaneously, resolving the contradiction between thin layer requirement for high flux and dense layer requirement for high selectivity
Solution Approach 2:
The patent utilizes phase transition of the solvent during the drying process. The solvent evaporates from the coated layer, transforming from liquid to gas phase, which enables the formation of a dense, pinhole-free polymer layer. This phase transition mechanism allows achieving both thin thickness and high density, simultaneously improving permeance and selectivity
2Manufacturing precision
If polymer solution is applied to inorganic porous support, then selective layer forms, but pore infiltration occurs leading to defects
Solution Approach 1:
The patent introduces a carefully selected solvent system as an intermediary between the polymer and the inorganic porous support. The solvent composition (mixing non-solvent and solvent in specific ratios) controls the polymer solution's interaction with the porous support, preventing penetration into pores while enabling uniform coating on the surface. This intermediary solvent system resolves the contradiction between forming a complete selective layer and avoiding pore infiltration
Solution Approach 2:
The patent adjusts multiple parameters of the polymer solution including solvent composition, concentration, and temperature to control the coating process. By optimizing these parameters, the solution maintains appropriate viscosity and surface tension to coat the support surface uniformly without penetrating into the pores, thus achieving defect-free selective layers
3Manufacturing precision
If pure polymer membranes are used for gas separation, then selectivity is achieved, but thermal and mechanical stability is insufficient
Solution Approach 1:
The patent creates a composite membrane structure combining an inorganic porous support material with a polymer selective separation layer. The inorganic support provides mechanical strength and thermal stability, while the polymer layer provides gas separation selectivity. This composite approach resolves the contradiction between achieving high gas separation efficiency and maintaining sufficient thermal and mechanical stability
4Manufacturing precision
If the separation layer thickness is increased to improve selectivity, then gas separation efficiency increases, but permeance decreases proportionally
Solution Approach 1:
The patent optimizes the drying parameters (temperature, time, atmosphere) to achieve the thinnest possible selective separation layer that is still completely dense and pinhole-free. By controlling the solvent evaporation rate and final layer composition, the process produces layers with minimal thickness but maximum density, thus achieving high selectivity without sacrificing permeance
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 results in gas separation membranes with high permeance and selectivity, capable of withstanding thermal and mechanical loads, and effectively prevents pore infiltration, even with large-pore supports, enhancing their usability in membrane reactors.
Implementation Method 1
producing a polymer solution (P) which is physically gelatable by cooling
Implementation Method 2
contacting the polymer solution (P) produced or provided in step a) with a cooled inorganic porous support (T) such that the polymer solution (P) cools and physically gels
Implementation Method 3
drying the polymer gel layer on the inorganic porous support (T) to form a selective separation layer
Data Source
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AI summary
A method for producing a membrane, in particular a gas separation membrane, is described, wherein the membrane comprises an inorganic porous support and a selective separation layer applied thereto. A membrane, in particular a gas separation membrane, that can be produced or is produced according to such a method is also described, as well as the use of such a membrane for separating gas mixtures.