Monolithic Separation Membrane Defect Detection and Repair
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Solution Overview
Problem
Current defect inspection and repair methods for monolithic separation membrane structures are inadequate for detecting defects inside cells and do not provide a simple solution for repairing such defects, limiting the effectiveness of the separation membrane's performance.
Innovation Solution
A defect detection method that measures gas permeation or degree of vacuum in each cell, identifying cells with values outside the average plus a predetermined standard deviation as defective, followed by a repair method where polymer compounds are used to seal the defective cells, enhancing the separation coefficient and product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection method is used for defect detection, then the inspection process is simple, but defects inside cells cannot be detected
Solution Approach 1:
The patent replaces visual inspection (mechanical/optical system) with gas permeation measurement (physical field system). By introducing gas into cells and measuring permeation rates, the system detects defects inside cells that are invisible to visual inspection, while maintaining operational simplicity through automated measurement.
Solution Approach 2:
The patent uses gas as an intermediary substance to detect defects. The gas permeates through the separation membrane, and its permeation rate serves as an indicator of membrane integrity. This intermediary enables indirect detection of internal defects without direct visual access.
2Ease of repair
If direct repair method is used for defective cells, then the defect location is precisely addressed, but the repair process is complex and time-consuming
Solution Approach 1:
The patent divides the monolithic substrate into individual cells and identifies specific defective cells through gas permeation measurement. Each cell can be independently assessed and repaired, allowing precise defect localization without complex imaging or inspection procedures. The segmentation enables targeted repair of only problematic cells.
Solution Approach 2:
The patent employs a simple sealing material (epoxy resin or similar) that can be easily applied and cured to seal defective cells. Rather than attempting complex surgical repair of the membrane, the solution uses an inexpensive, easy-to-apply sealing material that permanently addresses the defect, prioritizing repair simplicity over preserving original membrane integrity.
3Productivity
If membrane area is increased to improve water permeability, then separation performance is enhanced, but the complexity of defect detection and repair increases
Solution Approach 1:
The gas permeation measurement system serves multiple functions: it detects defects, locates defective cells, and provides quantitative data for repair prioritization. This universal measurement approach works for monolithic substrates of any size or cell count, scaling easily without increasing system complexity. The same basic procedure applies regardless of the total number of cells.
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 method effectively detects and repairs defective cells, improving the separation coefficient of the monolithic separation membrane structure, thereby increasing product yield and maintaining separation performance under pressure.
Implementation Method 1
Each cell is pressurized with gas (having a molecular size not smaller than the pore size of the separation membrane) from outside of the cell, and the amount of permeation of the gas permeated into each cell is measured
Implementation Method 2
pressure is reduced for each cell, the degree of vacuum in the cell is measured
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
There is provided a simple defect detection method for detecting defects in a monolithic separation membrane structure in which a separation membrane is formed in the cells. In addition, there are provided a repair method for repairing a monolithic separation membrane structure having a defective cell and a repaired monolithic separation membrane structure. Each cell (4) is pressurized with gas from outside of the cell (4), the amount of permeation of the gas permeated into each cell (4) is measured, and a cell (4) having the amount of permeation greater than "average value of all cells + A" (wherein A is a predetermined value of σ to 6σ, where σ is the standard deviation) is considered to be defective. Alternatively, pressure is reduced for each cell (4), the degree of vacuum in each cell (4) is measured, and a cell (4) having the degree of vacuum worse than "average value of all cells + A" is considered to be defective. Then, a polymer compound (27) is poured into the defective cells (4) of the monolithic separation membrane structure (1) and cured so that the defective cells (4) are sealed. Alternatively, the polymer compound (27) formed in advance as the sealing member is inserted into the defective cells (4) to seal the defective cells (4).