Gas Separation Membrane With Polymer Pore Penetration for CO2 Permeability
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Solution Overview
Problem
Existing gas separation membranes face challenges with insufficient carbon dioxide gas permeability and adhesion issues between the separation layer and the porous substrate, particularly when using non-metallic materials like organic polymers.
Innovation Solution
A gas separation membrane design featuring a porous body with a polymer-based separation layer that penetrates into its pores, ensuring a ratio of penetration depth to layer thickness of 30% or more, combined with a manufacturing process that includes coating, energy application, and removal of uncured portions to enhance adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal coating film is formed in the small pores of the porous substrate by a plating method to achieve gas separation capability, then the gas separation performance is improved, but the carbon dioxide gas permeability becomes insufficient
Solution Approach 1:
The patent changes the material parameter from metal to polymer, and changes the structural parameter by forming a separation layer with controlled thickness (5-100 nm) and penetration depth into pores. This parameter optimization achieves both gas separation capability and sufficient carbon dioxide permeability that metal coatings cannot provide.
Solution Approach 2:
The patent creates a composite structure combining a porous substrate with a polymer separation layer. This composite material approach allows the porous substrate to provide mechanical strength and the polymer layer to provide selective gas separation, achieving both separation performance and high permeability simultaneously.
2Productivity
If a non-metallic material such as an organic material is used for the separation layer to improve carbon dioxide gas permeability, then the gas permeability is improved, but the adhesion between the separation layer and the porous substrate may not be sufficiently increased
Solution Approach 1:
The patent applies preliminary actions to the porous substrate surface including surface treatment, plasma treatment, or chemical treatment before forming the polymer separation layer. These preliminary treatments create active sites and improve surface energy, ensuring strong adhesion of the polymer layer to the substrate while maintaining high gas permeability.
Solution Approach 2:
The patent creates local quality differences by treating only the surface region of the porous substrate to enhance adhesion, while the bulk polymer layer maintains its high permeability properties. The separation layer penetrates into pores with controlled depth, creating different densities and properties at different locations.
3Strength
If the separation layer penetrates deeply into the pores to increase adhesion, then the adhesion is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies partial action by controlling the separation layer to penetrate only to a specific depth (5-100 nm) into the pores, which is sufficient to achieve strong adhesion without requiring complete pore filling. This controlled partial penetration simplifies manufacturing while achieving the adhesion goal.
Solution Approach 2:
The patent optimizes the penetration depth parameter to a specific range (5-100 nm) that provides sufficient adhesion strength. By setting this parameter within an optimal range rather than maximizing it, the manufacturing process becomes simpler and more controllable while achieving the required adhesion performance.
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 membrane achieves high carbon dioxide permeability and strong adhesion, maintaining a selective separation ratio while reducing energy input and manufacturing complexity.
Implementation Method 1
A portion of the separation layer penetrates the pores from the first main surface
Implementation Method 2
performing a treatment of applying energy to the coating film from a side opposite to the porous body to cure or solidify the coating film
Data Source
AI summary
A gas separation membrane for selectively permeating and separating carbon dioxide from a mixed gas containing the carbon dioxide includes: a sheet-shaped porous body having a first main surface and a second main surface which are in a front-and-rear relationship with each other, and pores connecting the first main surface and the second main surface; and a separation layer provided on the first main surface and formed of a polymer material. A portion of the separation layer penetrates the pores from the first main surface. A ratio B/A is 30% or more, where A is an average thickness of the separation layer, and B is a penetration depth of the separation layer into the porous body.