Mesoporous Silica Membrane Complex with Intermediate Barrier
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Solution Overview
Problem
Existing methods for forming mesoporous silica membranes on porous supports face challenges such as uneven thickness, poor coverage, and reduced CO2 permeance due to the infiltration of precursor solutions and the introduction of functional groups into all pores, leading to defects and reduced separation performance.
Innovation Solution
A separation membrane complex is developed, comprising a porous support with an intermediate polycrystalline membrane and a surface-layer separation membrane, where the intermediate membrane has impermeability to precursor solutions and functional group introduction solutions, allowing for uniform membrane formation and targeted functional group introduction only in the surface layer of the separation membrane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precursor solution is applied to a porous support to form a mesoporous silica membrane, then the membrane formation process can be initiated, but the precursor solution infiltrates into the porous support causing uneven thickness and poor coverage
Solution Approach 1:
The membrane structure is segmented into two distinct layers: an intermediate membrane layer formed first on the porous support, and a separation membrane layer formed subsequently. This segmentation prevents precursor solution infiltration into the support while enabling controlled membrane formation with uniform thickness.
Solution Approach 2:
The intermediate membrane is formed as a preliminary layer before applying the precursor solution for the separation membrane. This preliminary action creates a barrier that prevents precursor solution infiltration, thereby ensuring uniform thickness and good coverage of the final separation membrane.
2Reliability
If a functional group is introduced into all pores of a mesoporous silica membrane to enhance CO2 separation performance, then separation efficiency increases, but CO2 permeance is reduced
Solution Approach 1:
The functional group introduction is localized to specific regions rather than being applied uniformly throughout. The silane coupling agent is introduced into the separation membrane layer while excluding the intermediate membrane layer, creating local functionalization that maintains high CO2 permeance while achieving effective separation.
Solution Approach 2:
The intermediate membrane acts as an intermediary barrier that prevents the silane coupling agent from entering certain regions. This intermediary structure enables controlled functional group introduction only in the separation membrane layer, optimizing both separation efficiency and permeance.
3Manufacturing precision
If liquid paraffin is impregnated into a porous support to prevent precursor solution infiltration, then membrane coverage improves, but the method is difficult to apply to tube-type or monolith-type supports and creates great variation in membrane thickness
Solution Approach 1:
Instead of using liquid paraffin impregnation, the invention changes the approach by forming an inorganic intermediate membrane through hydrolysis and condensation reactions. This parameter change enables the method to be applied to various support shapes including tube-type and monolith-type supports while achieving uniform membrane coverage and thickness.
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
This approach enables the appropriate formation of separation membranes with increased permeance and high separation performance by preventing precursor solution infiltration and limiting functional group introduction to the surface layer, thereby enhancing the permeance of specific substances like CO2 while maintaining high separation efficiency.
Implementation Method 1
the intermediate membrane has impermeability to precursor solutions and functional group introduction solutions
Implementation Method 2
increase permeance of a predetermined substance in the separation membrane
Implementation Method 3
a functional group is introduced into pores of a surface layer which is away from the intermediate membrane
Data Source
AI summary
A separation membrane complex includes a porous support, an intermediate membrane which is a polycrystalline membrane formed on a surface of the support and has pores that are originated from a framework structure and have an average pore diameter smaller than that of pores in the vicinity of the surface of the support, and a separation membrane which is formed on the intermediate membrane and is an inorganic membrane having a regular pore structure. In the separation membrane, a functional group is introduced into pores of a surface layer thereof which is away from the intermediate membrane.