Multilayer Microfiltration Membrane with Silica Nanoparticle Coatings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ultrafiltration membranes face challenges in achieving high permeability and selectivity due to difficulties in controlling pore formation, leading to a trade-off between these two properties and being expensive to produce, limiting their broad application.
Innovation Solution
A multilayer article comprising a microporous membrane substrate with two coating layers of acid-sintered interconnected silica nanoparticles and a polymeric binder, which are applied using aqueous coating formulations and sintered at low temperatures, forming a continuous three-dimensional porous network for enhanced selectivity and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional ultrafiltration membrane methods are used to achieve high selectivity, then nanopore formation is possible, but permeability decreases and production cost increases
Solution Approach 1:
The membrane structure is segmented into multiple functional layers: a microporous support layer providing mechanical strength and high permeability, and nanoporous silica coating layers providing selectivity. This segmentation allows each layer to optimize for its specific function without compromising the other.
Solution Approach 2:
The invention uses composite materials combining organic polymeric microporous support with inorganic silica nanoporous coatings. This composite structure integrates the advantages of both materials: the polymer provides porosity and flexibility while the silica provides precise nanopore control and chemical stability.
2Manufacturing precision
If traditional ultrafiltration membrane methods are used to achieve high selectivity, then nanopore formation is possible, but production cost increases
Solution Approach 1:
The invention uses relatively inexpensive silica nanoparticles and polymeric materials that can be processed through simple coating and sintering operations, avoiding the need for expensive specialized equipment and complex manufacturing processes required by traditional ultrafiltration membrane methods.
Solution Approach 2:
The invention changes the manufacturing parameters from complex controlled pore formation processes to simpler coating deposition followed by low-temperature sintering. This parameter change simplifies the manufacturing process while achieving the desired nanopore structure through the self-organizing properties of silica nanoparticles.
3Manufacturing precision
If pore density is increased to improve selectivity, then filtration performance improves, but permeability decreases
Solution Approach 1:
The nanoporous silica layers are applied locally on the surface of the microporous support, creating a selective barrier only where needed. The bulk of the membrane structure retains the high permeability of the microporous support material, while the surface layers provide the necessary selectivity.
Solution Approach 2:
The invention utilizes the inherent porosity of silica nanoparticles to create a hierarchical pore structure. The microporous support provides large pores for high flux, while the nanoporous silica coating provides small pores for selectivity, allowing both high permeability and high selectivity to coexist.
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 multilayer article achieves improved selectivity, capable of selectively removing nanoparticles and reducing bacteriophages by significant factors, while being produced at a lower cost and higher rate compared to traditional methods.
Implementation Method 1
The first layer comprises a first polymeric binder and a plurality of acid-sintered interconnected first silica nanoparticles arranged to form a continuous three-dimensional porous network
Implementation Method 2
the multilayer article achieves improved selectivity, capable of selectively removing nanoparticles and reducing bacteriophages by significant factors
Data Source
AI summary
The present disclosure provides a multilayer article. The multilayer article includes a) a microfiltration membrane substrate; b) a first layer directly attached to the first major surface of the microfiltration membrane substrate; and c) a second layer directly attached to the first layer. The first layer includes a first polymeric binder and acid-sintered interconnected first silica nanoparticles arranged to form a continuous three-dimensional porous network. The second layer includes acid-sintered interconnected second silica nanoparticles arranged to form a continuous three-dimensional porous network. The present disclosure also provides a method for forming a multilayer article. The method includes (a) saturating a microfiltration membrane substrate with a liquid; (b) applying a first aqueous coating formulation to at least a portion of a first major surface of the microfiltration membrane substrate to form a coated substrate; (c) sintering the coated substrate, thereby forming a first layer; (d) applying a second aqueous coating formulation to the first major surface of the first layer to form a twice-coated substrate; and (e) sintering the twice-coated substrate.