Hybrid Matrix Membrane Support for High-Pressure Separation
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Solution Overview
Problem
Existing porous membranes used in separation processes, such as hydrogen production, lack uniform permeability and structural strength to handle high pressures effectively, leading to potential membrane rupture and inefficiencies.
Innovation Solution
A porous hybrid matrix membrane support is developed, comprising a densified porous mesh layer and a densified non-woven filament layer, which are diffusion-bonded to provide structural support and uniform permeability suitable for high-pressure applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous membrane is used to separate gaseous constituents in high-pressure reforming processes, then separation capability is improved, but the membrane structure deforms and ruptures due to lack of structural strength
Solution Approach 1:
The patent employs a composite structure combining a mesh support layer with a filament layer to create a hybrid membrane support system. The mesh provides structural strength and pressure resistance, while the filament layer provides permeability and uniformity. This composite approach resolves the contradiction by integrating materials with complementary properties to achieve both strength and separation capability.
Solution Approach 2:
The patent applies different properties to different layers of the membrane support structure. The mesh layer is optimized for structural strength and pressure resistance, while the filament layer is optimized for permeability and uniform flow distribution. This local differentiation allows each layer to perform its specific function optimally, resolving the contradiction between strength and separation capability.
2Strength
If a mesh structure is used to provide structural support, then strength is improved, but permeability uniformity deteriorates
Solution Approach 1:
The patent merges two different structural approaches: a mesh layer for strength and a filament layer for uniform permeability. The combination creates a hybrid structure where the mesh provides the mechanical framework and the filament layer fills the spaces between mesh elements to ensure uniform flow distribution across the entire membrane surface, resolving the contradiction between strength and permeability uniformity.
Solution Approach 2:
The patent uses a composite construction with a mesh support layer combined with a filament layer to achieve both structural strength and uniform permeability. The mesh layer provides the necessary mechanical strength while the filament layer ensures uniform flow distribution, creating a composite material system that satisfies both requirements simultaneously.
3Strength
If fiber and mesh are combined to improve both strength and permeability, then both properties are improved, but manufacturing complexity increases due to joining difficulties
Solution Approach 1:
The patent employs diffusion bonding as a joining method that utilizes changes in material properties under controlled temperature and pressure conditions. By heating the mesh and filament layers to specific temperatures and applying pressure, the materials diffuse at the interface to create a strong bond. This parameter-based joining approach simplifies the manufacturing process compared to traditional mechanical joining methods while maintaining the integrity of the hybrid structure.
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 hybrid matrix membrane support achieves substantial uniform permeability across its surface, with a variability of 25% or less, and can withstand higher pressures without rupturing, enhancing the efficiency and reliability of membrane separation processes.
Implementation Method 1
The mesh support layer and the filament layer can be diffusion bonded to form the hybrid matrix membrane support
Data Source
AI summary
The invention provides a porous hybrid matrix membrane support having at least one porous mesh layer of mesh densified to form a membrane mesh support and at least one porous filament layer of filaments that are generally non-woven, densified to form a membrane filament support. The filament layer is densified to provide a sufficiently small crevice depth in the membrane filament support that can help protect a membrane layer on the membrane filament support from rupturing. The membrane mesh support and the membrane filament support with micro-smooth surfaces can be integrally joined by diffusion bonding to resist separation across the adjoining surfaces. The combined, diffusion bonded support of both types of layers provide structural support sufficient for high pressures and provide substantial uniform permeability across the face of the structural support.