Honeycomb Ceramic Separation Membrane Slit Crack Prevention
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Solution Overview
Problem
Honeycomb shaped ceramic separation membranes with slit cells are prone to crack formation, leading to strength deterioration and compromised separation performance due to thermal expansion coefficient mismatch between bonding materials and aggregate particles in the intermediate layer.
Innovation Solution
A honeycomb shaped porous ceramic body with a substrate and intermediate layer made of alumina, where the bonding material has a thermal expansion coefficient equal to or higher than the aggregates, reducing tensile stress and preventing slit crack generation, and a top layer with finer particles for enhanced strength and separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bonding material has a smaller thermal expansion coefficient than the aggregate particles, then the intermediate layer can be formed with good bonding, but slit cracks are easily generated in the vicinity of slit cells leading to strength deterioration
Solution Approach 1:
The patent changes the thermal expansion coefficient parameter of the bonding material from being smaller than the aggregate particles to being equal to or larger than the aggregate particles. This parameter change prevents the generation of tensile stress during thermal processing, thereby eliminating slit cracks and improving both strength and reliability.
Solution Approach 2:
The patent explicitly utilizes thermal expansion principles by selecting a bonding material with a thermal expansion coefficient equal to or larger than that of the aggregate particles. This ensures that both materials expand and contract at similar rates during temperature changes, preventing differential stress that leads to cracking.
2Reliability
If the bonding material has a thermal expansion coefficient equal to or higher than the aggregate particles, then tensile stress is reduced and slit cracks are prevented, but the bonding strength between particles may be compromised
Solution Approach 1:
The patent employs composite materials by combining aggregate particles with a bonding material that has specific thermal expansion properties. This composite structure allows the bonding material to maintain adequate bonding strength while simultaneously preventing crack generation through matched thermal expansion behavior.
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 solution effectively inhibits crack formation, maintaining high internal pressure breaking strength and separation performance, ensuring a durable and efficient separation membrane structure.
Implementation Method 1
the intermediate layer has a structure in which aggregate particles are bonded to one another by an inorganic bonding material having a thermal expansion coefficient equal to or higher than that of the aggregate particles
Data Source
AI summary
A separation membrane structure has partition walls including a honeycomb shaped porous ceramic body provided with a large number of pores, and cells to become through channels of a fluid are formed by the partition walls. The cells include separation cells and slit cells. In the separation cells, the intermediate layer is disposed on the surface of a substrate, and a separation layer is further formed. The intermediate layer has a structure where aggregate particles are bonded to one another by an inorganic bonding material having a thermal expansion coefficient equal to or higher than that of the aggregate particles.