Porous Ceramic Laminate Pore Orientation for Low-Resistance Separation
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Solution Overview
Problem
Existing porous ceramic bodies face high resistance to fluid permeation when equipped with a functional layer, which can lead to clogging and increased operational challenges.
Innovation Solution
A porous ceramic layer with a pore angle θL of 68° to 112° and a layered structure with two porous layers, where the second layer has a smaller pore diameter than the first, composed of metal oxides, particularly alumina, to reduce permeation resistance and prevent clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a functional layer is formed on the porous ceramic body to enable separation functions, then the separation performance is improved, but the resistance to fluid permeation increases
Solution Approach 1:
The patent employs a porous ceramic layer with specifically controlled pore structures (pore angle θL of 68° to 112°, porosity of 30% to 60%, and pore diameter of 0.01 μm to 10 μm) as the functional layer. The porous structure allows fluid to pass through while maintaining separation functionality, thus reducing permeation resistance compared to dense functional layers while achieving reliable separation performance.
Solution Approach 2:
The patent creates a composite structure consisting of a porous ceramic substrate combined with a porous ceramic functional layer. This composite material approach allows the functional layer to maintain both separation capability and low permeation resistance by optimizing the pore structure parameters, achieving a balance between reliability and productivity.
2Measurement precision
If the functional layer is made denser to improve separation capability, then separation precision is improved, but fluid permeation resistance increases and clogging occurs
Solution Approach 1:
The patent applies local quality by creating a functional layer with spatially optimized pore characteristics. The pore angle θL is controlled to be between 68° and 112° relative to the thickness direction, creating a specific orientation distribution that provides both separation precision and low resistance. The porosity (30%-60%) and pore diameter (0.01 μm-10 μm) are locally optimized in the functional layer to prevent clogging while maintaining separation capability.
Solution Approach 2:
The patent utilizes parameter changes by precisely controlling key structural parameters of the porous ceramic layer: pore angle θL (68°-112°), porosity (30%-60%), and pore diameter (0.01 μm-10 μm). By optimizing these parameters, the functional layer achieves high separation precision without the harmful effects of dense structures, such as high permeation resistance and clogging.
Data Source
Figure 1~2
AI summary
An object of the present invention is to provide a porous ceramic layer and a porous ceramic layered body in which when a functional layer is layered on top, the resistance of the functional layer can be small. The porous ceramic layer includes ceramic trabeculae and voids, wherein, when the thickness direction is defined as the z axis, the pore angle θL, which is an angle made by the z axis and a spheroidally approximate major axis determined by analyzing the void using a three-dimensional Mean Intercept Length method, is 68° to 112°.