Monolithic Separation Membrane with Optimized Cell Dimensions
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Solution Overview
Problem
Existing monolithic separation membrane structures face challenges in reducing weight and increasing compactness while maintaining permeation performance, particularly after high-temperature alkali processing.
Innovation Solution
A monolithic separation membrane structure with a monolithic base, an intermediate layer, and a separation membrane, where the inner diameter of filtration cells is between 1.0 mm to 2.0 mm, the partition wall thickness is between 0.05 mm to 0.2 mm, and the intermediate layer thickness is between 20 μm to 100 μm, enhancing the total surface area and reducing weight and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the partition wall thickness is reduced to decrease weight and increase compactness, then the weight and volume are reduced, but the structural strength and stability deteriorate
Solution Approach 1:
The invention changes the parameter of partition wall thickness to a specific range (0.05-0.2 mm) that optimizes the balance between weight reduction and structural strength. This parameter change allows the structure to be lightweight while maintaining sufficient strength through precise dimensional control.
2Volume of stationary object
If the inner diameter of filtration cells is reduced to increase compactness, then the volume is decreased, but the permeation performance deteriorates
Solution Approach 1:
The invention optimizes the inner diameter parameter of filtration cells to a specific range (1.0-2.0 mm) that achieves the best balance between compactness and permeation performance. This parameter optimization ensures sufficient flow capacity while minimizing the overall device volume.
3Weight of moving object
If the thickness of intermediate layer is reduced to decrease weight, then the weight is reduced, but the permeation performance deteriorates
Solution Approach 1:
The invention optimizes the intermediate layer thickness to a specific range (20-100 μm) that balances weight reduction with permeation performance maintenance. This precise parameter control allows the intermediate layer to be thin enough to reduce weight but thick enough to preserve filtration efficiency.
4Volume of stationary object
If the partition wall thickness is reduced below 0.2 mm, then the compactness is increased, but the deformation during firing increases causing cell closure
Solution Approach 1:
The invention establishes a minimum partition wall thickness of 0.05 mm that prevents deformation and cell closure during high-temperature firing while still achieving compactness. This parameter boundary ensures structural integrity is maintained during the critical manufacturing process.
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 configuration enables a reduction in weight and increase in compactness while maintaining permeation performance, as demonstrated by increased ethanol permeation rates and surface area per unit volume and weight, with improved structural integrity and reduced pressure loss.
Implementation Method 1
a separation membrane that is formed on an inner surface of the intermediate layer
Implementation Method 2
Specification of Japanese Patent No. 5599785 discloses that the partition wall thickness is preferably greater than or equal to 0.2 mm in order to suppress large deformation of the monolithic base as a result of firing during manufacture
Data Source
AI summary
The monolithic separation membrane structure includes a monolithic base, an intermediate layer and a separation membrane. The monolithic base has a plurality of filtration cells extending from a first end face to a second end face. The intermediate layer is formed on an inner surface of the filtration cells. The separation membrane is formed on an inner surface of the intermediate layer. An inner diameter not including the intermediate layer and the separation membrane of the plurality of respective filtration cells is greater than or equal to 1.0 mm to less than or equal to 2.0 mm. A partition wall thickness not including the intermediate layer and the separation membrane of the shortest portion of two adjacent filtration cells of the plurality of filtration cells is greater than or equal to 0.05 mm to less than 0.2 mm. A thickness of the intermediate layer is greater than or equal to 20 μm to less than 100 μm.