Hollow Fiber Membrane Hexagonal Voids High Throughput
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Solution Overview
Problem
Hollow fiber membranes used for fluid filtration often lack high throughput performance, and existing methods for producing them are inefficient or environmentally harmful.
Innovation Solution
A method for producing hollow fiber membranes with a controlled pore structure, utilizing a polymer matrix and dissolvable silica nanoparticles to create pores with specific sizes and hexagonal packing, allowing for high void fractions and efficient fluid filtration, using environmentally benign solvents and processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hollow fiber membranes are used for fluid filtration, then filtration function is provided, but throughput performance is insufficient
Solution Approach 1:
The patent employs a porous bulk structure with controlled pore sizes (50-1000 nm) arranged in hexagonal packing patterns. This porous architecture enables high void fractions (66-73 vol.%) while maintaining precise filtration capabilities, directly resolving the contradiction between throughput and filtration performance by optimizing the pore structure for both flow efficiency and particle rejection
Solution Approach 2:
The invention systematically varies critical parameters including pore size (50-1000 nm range), void fraction (66-73 vol.%), and pore arrangement (hexagonal packing) to achieve optimal balance between throughput and filtration. By controlling these parameters during membrane formation, the patent simultaneously enhances productivity while maintaining reliable filtration function
2Ease of manufacture
If existing membrane production methods are used, then membranes can be manufactured, but the processes are inefficient and environmentally harmful
Solution Approach 1:
The patent converts the traditionally harmful role of solvents and chemical additives into a beneficial forming mechanism. By using environmentally benign solvents and leveraging controlled phase separation during membrane formation, the process transforms potential environmental hazards into useful structure-defining elements, achieving both ease of manufacture and environmental sustainability
Solution Approach 2:
The invention changes the chemical parameters of the membrane formation process by using environmentally friendly solvents and controlled precipitation methods instead of harsh chemicals. This parameter change enables efficient membrane production while eliminating harmful environmental factors, simultaneously improving ease of manufacture and reducing environmental impact
3Productivity
If high void fractions are achieved through particle packing, then throughput is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates particles with predetermined sizes and shapes into the membrane matrix during the formation process. This preliminary arrangement of particles before final membrane consolidation enables high void fractions (66-73 vol.%) to be achieved through a single integrated manufacturing step, avoiding complex post-processing operations and reducing overall manufacturing complexity while maintaining high fluid flow efficiency
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 membranes exhibit enhanced filtration performance with high throughput and reduced environmental impact, achieving pore sizes and void fractions that improve fluid flow efficiency while being safer and more sustainable to produce.
Implementation Method 1
utilizing a polymer matrix and dissolvable silica nanoparticles to create pores with specific sizes
Implementation Method 2
the porous bulk comprises at least a first region including: a) a first set of pores having a first controlled pore size and having outer rims
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~4A
AI summary
Disclosed is a hollow fiber membrane having hexagonal voids, suitable for use in high throughput filtration applications. Thus, the membrane includes (i) an inner surface; (ii) an outer surface; and (iii) a porous bulk disposed therebetween, wherein the porous bulk comprises at least a first region including: a) a first set of pores having a first controlled pore size and having outer rims; b) a second set of pores connecting the outer rims of the first set of pores, wherein the pore size of the first set of pores is greater than the pore size of the second set of pores; and c) a polymer matrix supporting the first set of pores. Also disclosed is a method for preparing such hollow fiber membranes, which involves coating a filament with a coating composition that includes a membrane-forming polymer and dissolvable nanoparticles, followed by phase invention, and dissolving of the nanoparticles. The filament is removed to obtain the hollow fiber membrane.