MWW/DDR Zeolite Gas Separation Membrane Epitaxial Growth

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional zeolite-based gas separation membranes suffer from reduced separation performance due to defects larger than the pore size, making it difficult to manufacture high-performance membranes.

Innovation Solution

A gas separation membrane is developed where MWW type zeolite and DDR type zeolite are epitaxially grown alternately, with one type of zeolite being grown on the other, using a method involving hydrothermal synthesis and specific precursor solutions to enhance structural continuity and separation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional zeolite-based gas separation membranes are manufactured, then the membrane structure is formed, but defects larger than pore size are generated reducing separation performance

Engineering Contradiction:

Improveseparation performanceVSAvoiddefect-free structure

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The membrane is divided into multiple layers with different zeolite types (MWW and DDR) arranged in alternating segments. Each layer serves a specific function in the separation process, and the segmented structure allows for better control of defects at interfaces while maintaining overall separation performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite zeolite structures combining MWW and DDR types in alternating layers. This composite approach leverages the complementary properties of each zeolite type to achieve superior separation performance while the epitaxial growth ensures structural continuity that minimizes defects.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If heterogeneous zeolites are epitaxially grown alternately, then separation efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidmanufacturing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing process employs periodic alternation between MWW and DDR zeolite layer formation. This periodic structure is achieved through cyclic hydrothermal synthesis processes that deposit alternating layers, simplifying the control of complex heterogeneous growth while maintaining high separation efficiency.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent controls the synthesis conditions (temperature, pressure, precursor composition, pH) to enable epitaxial growth of alternating zeolite layers. By carefully adjusting these parameters, the manufacturing process achieves complex heterogeneous structures through controlled chemical transformations rather than mechanical assembly.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If zeolite layers are deposited to fill defects, then structural continuity is enhanced, but manufacturing time increases

Engineering Contradiction:

Improvestructural continuityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The first zeolite layer is deposited and partially dried before the second zeolite layer is applied. This preliminary action creates a stable substrate that facilitates rapid epitaxial growth of the subsequent layer, reducing overall manufacturing time while ensuring structural continuity at interfaces.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hydrothermal synthesis process continues uninterrupted to grow both MWW and DDR layers in sequence without removing the membrane between steps. This continuous process maintains structural integrity and reduces manufacturing time compared to discrete deposition and handling steps.

Inventive Principle:

Principle #20Continuity of useful action

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 membrane achieves improved gas separation efficiency, particularly for carbon dioxide, by reducing defects and increasing the continuity of the zeolite structure, leading to enhanced separation performance compared to conventional membranes.

Implementation Method 1

MWW type zeolite and DDR type zeolite which are epitaxially grown alternately with each other and one on top of the other

Methodology Applied

Scientific EffectEpitaxy: Epitaxy

Implementation Method 2

performing first hydrothermal synthesis on the first zeolite precursor solution to form first zeolite in a form of a plurality of first zeolite particles

Methodology Applied

Scientific EffectHydrothermal synthesis:

Implementation Method 3

acts as a molecular sieve made of alumina-silica having a regular three-dimensional framework structure

Methodology Applied

Scientific EffectMolecular sieve: Molecular Sieve

Data Source

PatentUS11731086B2Gas separation membrane containing heterogeneous zeolites and preparation method thereof

Publication Date: 2023.08.22 KOREA UNIV RES & BUSINESS FOUND

AI summary

Disclosed are a MWW/DDR type gas separation membrane comprising at least one MWW type zeolite and at least one DDR type zeolite and a method for preparing the same. One of the MWW type zeolite and the DDR type zeolite is disposed on the other thereof, wherein at least one of the MWW type zeolite and the DDR type zeolite is epitaxially grown. In the gas separation membrane, the DDR type zeolite is epitaxially grown from the MWW type zeolite, or the MWW type zeolite is epitaxially grown from the DDR type zeolite. Thus, the MWW/DDR type gas separation membrane is synthesized using a structural continuity of the MWW type zeolite and the DDR type zeolite. Thus, the gas separation membrane has excellent separation efficiency.