Intermixed Gas Separation Membrane Layers for High-Pressure CO2/CH4

Solution Overview

Problem

Existing composite gas separation membranes face challenges in maintaining robustness and efficiency at high pressures, particularly in distinguishing between gases like CO2 and CH4, with a low tendency to separate layers and ensuring good gas flux and discrimination.

Innovation Solution

A composite membrane design featuring a porous support, a gutter layer, and a discriminating layer where at least 10% of the discriminating layer is intermixed with the gutter layer, enhancing adhesion and mechanical strength while maintaining gas permeance and selectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the discriminating layer is applied as a separate distinct layer on the gutter layer, then the membrane structure is simpler to manufacture, but the layers have a high tendency to separate and peel at high pressures

Engineering Contradiction:

Improveease of manufactureVSAvoidlayer adhesion

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the discriminating layer and gutter layer into a single intermixed layer where the discriminating polymer penetrates into the gutter layer matrix. This combination creates a unified structure that eliminates the interface between layers, preventing separation and peeling while maintaining manufacturing simplicity through a single application process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a composite structure where the discriminating layer and gutter layer are intermixed at the molecular level. The discriminating polymer forms a composite matrix with the gutter layer material, resulting in a unified composite material that exhibits both the gas separation properties of the discriminating layer and the mechanical stability of the gutter layer.

Inventive Principle:

Principle #40Composite materials

2Productivity

If the discriminating layer is made thinner to improve gas flux, then the gas permeance increases, but the layer becomes more prone to defects and reduced selectivity

Engineering Contradiction:

Improvegas fluxVSAvoidlayer uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating an intermixed structure where the discriminating polymer is distributed throughout the gutter layer matrix. This allows the effective discriminating thickness to be reduced for higher flux while the intermixed network throughout the gutter layer provides continuous selectivity pathways, preventing defects that would occur in uniformly thin layers.

Inventive Principle:

Principle #3Local quality

3Reliability

If the membrane is designed for high pressure operation, then the gas separation efficiency improves, but the layers are more likely to separate and delaminate

Engineering Contradiction:

Improveseparation efficiencyVSAvoidlayer adhesion

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges the discriminating layer and gutter layer into a single intermixed layer where the discriminating polymer penetrates into the gutter layer matrix. This combination creates a unified structure that eliminates the interface between layers, preventing separation and peeling while maintaining manufacturing simplicity through a single application process.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If the discriminating layer is made thicker to improve gas selectivity, then the discrimination between gases improves, but the gas flux decreases

Engineering Contradiction:

ImproveselectivityVSAvoidgas flux

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies local quality by creating an intermixed structure where the discriminating polymer is distributed throughout the gutter layer matrix. This allows the effective discriminating thickness to be reduced for higher flux while the intermixed network throughout the gutter layer provides continuous selectivity pathways, preventing defects that would occur in uniformly thin layers.

Inventive Principle:

Principle #3Local quality

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 results in robust membranes with improved adhesion between layers, reduced tendency to peel, and enhanced performance in gas separation, particularly for CO2 and CH4, at high pressures, with increased gas flux and selectivity.

Implementation Method 1

The solvents used to form the discriminating layer must not attack the gutter layer, hence the discriminating layer of '280 will not permeate into the gutter layer

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 2

the gutter and discriminating layer are adhered together very strongly due to the abovementioned intermixing

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

the porous support is typically open pored, relative to the discriminating layer

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 4

a discriminating layer; wherein at least 10% of the discriminating layer is intermixed with the gutter layer

Methodology Applied

Scientific EffectPermeation: Permeation

Data Source

PatentUS10005043B2Gas separation membranes with intermixed layers

Publication Date: 2018.06.26 YESTAR ADVANCED MATERIALS (HK) CO LTD

AI summary

A composite membrane comprising:a) a porous support;b) a gutter layer; andc) a discriminating layer;wherein at least 10% of the discriminating layer is intermixed with the gutter layer.