Poly(4-Methyl-1-Pentene) Separation Membrane for Low Leakage
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Solution Overview
Problem
Existing separation membranes made from poly(4-methyl-1-pentene) face challenges in achieving high strength, low leakage, and high gas permeability due to issues with porosity and dense layer integrity during manufacturing processes.
Innovation Solution
A separation membrane with specific ranges for rigid amorphous content and porosity, along with a dense layer on at least one surface, optimized through controlled manufacturing conditions to enhance strength and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dense layer is made thin to increase gas permeability, then gas permeability is improved, but the membrane develops through-holes and leakage increases
Solution Approach 1:
The membrane is designed with a dense layer having different properties in different regions: the first region maintains high density with controlled pore size to prevent leakage, while the second region has adjusted density to maintain strength. This local differentiation allows the thin dense layer to achieve high gas permeability without developing through-holes that cause leakage.
Solution Approach 2:
The membrane employs a composite structure combining a dense layer with a porous support layer. The dense layer provides gas separation and permeability, while the porous support layer provides mechanical strength. This composite approach allows the dense layer to be made thin for high permeability while the support layer prevents through-hole formation and leakage.
2Strength
If stretching is increased to improve strength, then membrane strength is improved, but pores in the dense layer open up causing leakage
Solution Approach 1:
Different regions of the dense layer are designed with different pore structures: the first region has smaller pores that remain closed during stretching to prevent leakage, while the second region has larger pores that provide mechanical strength. This local quality differentiation allows the membrane to achieve high strength through controlled stretching without opening pores that would cause leakage.
3Productivity
If porosity is increased to improve gas permeability, then gas permeability is improved, but membrane strength decreases
Solution Approach 1:
The membrane is segmented into functionally distinct layers: a dense layer for gas separation and permeability, and a porous support layer for mechanical strength. The dense layer is further segmented into two regions with different pore characteristics. This segmentation allows each layer to optimize its function without compromising the other, achieving high gas permeability while maintaining membrane strength.
Solution Approach 2:
The membrane combines a dense layer with a porous support layer in a composite structure. The dense layer provides the necessary gas permeability with controlled porosity, while the porous support layer provides mechanical strength. This composite material approach resolves the contradiction by distributing the functional requirements across different materials and layers.
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 high strength, low leakage, and maintains high gas permeability by balancing rigid amorphous content and porosity, ensuring effective gas exchange.
Implementation Method 1
a polymer solution in which a polyolefin-based polymer is dissolved in a good solvent is extruded from a spinneret at a temperature higher than the melting point of a polyolefin resin, and this polymer solution is brought into contact with a cooling solvent to form an asymmetric structure having a dense layer on one surface by thermally induced phase separation
Data Source
AI summary
A separation membrane has high strength and low leakage property while maintaining high gas permeability using poly(4-methyl-1-pentene) excellent in chemical resistance and gas permeability. The separation membrane contains poly(4-methyl-1-pentene) as a main component, in which a ratio RA of a rigid amorphous of poly(4-methyl-1-pentene) in the separation membrane is 43% or more and 60% or less, a porosity is 30% or more and 70% or less, and a dense layer is provided on at least one surface.