Hydrophilic Gutter Layer for Delamination-Resistant Gas Membranes
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Solution Overview
Problem
Existing gas separation membranes face issues with premature delamination due to poor bonding between hydrophobic intermediate gutter layers, such as polydimethylsiloxane, and the support and gas separation layers, which can be exacerbated by the need for additional surface activation steps, increasing production costs.
Innovation Solution
A gas separation membrane design incorporating a hydrophilic polyurethane gutter layer with a polyfunctional aziridine liquid crosslinker, combined with a gas separation layer comprising ionic liquids and polyether block amides, enhances compatibility and adhesion without requiring extra activation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydrophobic gutter layer (e.g., PDMS) is used, then gas permeability is maintained, but bonding compatibility with support and gas separation layers deteriorates, leading to premature delamination
Solution Approach 1:
The patent changes the chemical parameter of the gutter layer from hydrophobic to hydrophilic by selecting polymers with hydrophilic functional groups (e.g., carboxyl, hydroxyl, amine groups). This parameter change improves bonding compatibility with both the support layer and gas separation layer, preventing delamination while maintaining gas permeability through appropriate pore structure design.
Solution Approach 2:
The patent employs composite material design by combining hydrophilic polymers with specific functional groups in the gutter layer. The gutter layer comprises a mixture of polymer materials including those with carboxyl groups, hydroxyl groups, or amine groups, creating a composite structure that achieves both mechanical bonding strength and gas permeability without requiring additional surface treatment steps.
2Strength
If surface activation treatments (plasma or functionalization) are applied to improve bonding, then interlayer adhesion is enhanced, but production complexity and costs increase
Solution Approach 1:
The patent implements self-service by designing the gutter layer material itself to possess inherent bonding capability through hydrophilic functional groups. The material automatically provides the necessary adhesion properties without requiring external surface activation treatments, thereby simplifying the production process and reducing costs while maintaining strong interlayer bonding.
Solution Approach 2:
The patent extracts and eliminates the need for separate surface activation steps from the production process. By incorporating bonding functionality directly into the gutter layer material composition, the patent removes the requirement for additional plasma treatment or surface functionalization steps, streamlining the manufacturing process.
3Reliability
If silicon-containing materials are used in the gutter layer, then gas permeability is achieved, but compatibility with ionic liquid-based gas separation layers deteriorates
Solution Approach 1:
The patent changes the chemical composition parameter of the gutter layer by eliminating silicon-containing materials and replacing them with hydrophilic polymers containing oxygen, nitrogen, or other non-silicon-based functional groups. This parameter change improves compatibility with ionic liquid-based gas separation layers while maintaining gas permeability through controlled pore structure.
Solution Approach 2:
The patent promotes material homogeneity by selecting gutter layer materials with chemical composition characteristics that are compatible with ionic liquids. The use of hydrophilic polymers with functional groups similar in nature to those found in ionic liquids creates a more homogeneous chemical environment across the membrane layers, improving overall system compatibility.
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 exhibits improved gas selectivity and permeability, with reduced silicon content and enhanced bonding, leading to better film quality and reduced production costs.
Implementation Method 1
a gutter layer, wherein the gutter layer comprises a hydrophilic polymer and a crosslinker
Implementation Method 2
a gas separation layer, wherein the gas separation layer is a gas discriminating layer
Data Source
Figure 1
AI summary
Described herein are gas separation membranes that provide improved compatibility between the gutter layer and the porous support and/or the separation layer for gases. Such composite membranes have a high water/air selectivity in permeability.