Non-oxide ceramic filtration element sintering
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Solution Overview
Problem
The existing methods for manufacturing non-oxide ceramic filtration membranes require high temperatures and an inert atmosphere, making them energy-intensive and costly, while also limiting the adjustment of pore size and reducing the mechanical strength and chemical resistance of the membranes.
Innovation Solution
The process involves using a support structure coated with a suspension of first and second particles, where the second particles, such as metal oxides, aid in sintering at lower temperatures without the need for an inert atmosphere, enhancing mechanical strength and maintaining filtration properties like pore size and zeta potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-oxide ceramic nanoparticles are sintered at very high temperatures under exclusion of oxygen, then the membrane achieves excellent resistance to corrosive media and low fouling tendency, but the manufacturing process becomes difficult and expensive
Solution Approach 1:
Metal oxide nanoparticles serve as an intermediary substance that facilitates sintering of non-oxide ceramic nanoparticles at lower temperatures. The metal oxide particles act as a eutectic forming agent that reduces the sintering temperature requirement while maintaining the chemical stability and corrosion resistance properties of the final membrane structure.
2Ease of manufacture
If sintering temperature is reduced by using additives, then the manufacturing process becomes easier, but the exact adjustment of pore size becomes difficult and the quality is reduced
Solution Approach 1:
The invention changes the physical and chemical parameters of the sintering process by introducing metal oxide nanoparticles with specific properties (size, composition, surface area). By adjusting the concentration and type of metal oxide additive, the sintering temperature can be precisely controlled while maintaining pore size uniformity and membrane quality.
3Reliability
If conventional sintering methods are used for non-oxide ceramics, then the membrane achieves high chemical stability, but the energy consumption is very high
Solution Approach 1:
The invention utilizes phase transition phenomena during sintering, where metal oxide nanoparticles undergo eutectic melting at lower temperatures to form liquid bridges between non-oxide ceramic particles. This phase transition enables densification and bonding at reduced temperatures, significantly lowering energy consumption while preserving the chemical stability of the final membrane.
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 reduces energy consumption and production costs, allows for easier adjustment of pore size, and improves the mechanical and chemical stability of the filtration membranes, enabling efficient separation of high molecular weight compounds without the need for an inert atmosphere.
Implementation Method 1
In the course of drying and sintering, the precursor is oxidized to the corresponding metal oxide forming membrane layers with small pore sizes
Implementation Method 2
The process of manufacture of oxidic ceramic filter membranes is usually achieved by a sol-gel process, in which a support surface is coated with a sol containing a precursor metal compound
Implementation Method 3
contacting the support surface with the coating suspension for a duration of time, preferably for 10 to 120 seconds, more preferably for 60 seconds or for 30 seconds; removing excess coating suspension without removing a residual film of coating suspension
Implementation Method 4
drying the residual film, preferably for 2 to 6 h at a temperature in the range of from 60 °C to 90 °C
Implementation Method 5
The present invention relates to a process for the manufacture of a ceramic filter membrane for nanofiltration purposes in liquid purification processes
Data Source
Figure 1
Figure 2A~2B
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AI summary
The present disclosure relates to a method of preparing oxide and non-oxide ceramic filtration elements with a high abrasion resistance, wherein the process of manufacture allows low sinter temperatures in the presence of atmospheric oxygen, wherein the obtained non-oxide filter membrane shows typical behavior of non-oxide ceramic filtration elements.