Nanoparticle Intermediate Layer for Acid Gas Separation Membranes

An intermediate layer is introduced between the separation functional layer and the porous support member. This intermediate layer acts as a mediator that enables the use of extremely thin separation functional layers (5 μm or less) while maintaining structural integrity and separation performance. The intermediate layer provides mechanical support to the ultra-thin separation layer, preventing it from collapsing or developing defects that would compromise separation performance.

The membrane employs a composite structure consisting of multiple functional layers: a separation functional layer made of specific polymers (polyether block amide or polyvinylidene fluoride), an intermediate layer with specific mechanical properties, and a porous support member. This composite material approach allows each layer to be optimized for its specific function - the separation layer for high selectivity, the intermediate layer for mechanical support, and the support member for structural stability - thereby achieving both high permeation rate and maintained separation performance.

The membrane structure is segmented into three distinct functional layers: the separation functional layer (5 μm or less), the intermediate layer (5-50 μm), and the porous support member. This segmentation allows the ultra-thin separation layer to be supported by the intermediate and support layers, distributing mechanical stresses and preventing failure of the thin separation layer while maintaining its high permeation capability.

The intermediate layer serves as a mediator between the ultra-thin separation functional layer and the porous support member. It provides mechanical reinforcement to the separation layer without significantly impeding gas transport, enabling the separation layer to be made extremely thin for high permeation rates while maintaining adequate mechanical strength through the supportive intermediate layer.