Porous Support Layering for Separation Membrane Permeation
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Solution Overview
Problem
The reduction in average pore diameter of the surface layer in separation membrane structures leads to reduced porosity and a decrease in the permeation amount, resulting in a reduced effective surface area and permeation efficiency.
Innovation Solution
A porous support structure is designed with a base body, an intermediate layer, a supporting layer, and a topmost layer, where the porosity ratio of the topmost layer to the supporting layer is greater than or equal to 1.08 and the thickness ratio is less than or equal to 0.9, enhancing permeation while maintaining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the average pore diameter of the surface layer is reduced to enhance membrane formation characteristics, then the separation performance is improved, but the porosity of the surface layer is reduced and the permeation amount decreases
Solution Approach 1:
The invention applies local quality by creating distinct layers with different pore diameter characteristics. The surface layer has smaller average pore diameter (0.003-0.03 μm) for high separation performance, while the supporting layer has larger average pore diameter (0.03-0.5 μm) to maintain porosity (40-60%) and ensure sufficient permeation passages. This spatial differentiation of pore characteristics resolves the contradiction between separation precision and permeation productivity.
2Productivity
If the porosity of the surface layer is increased to enhance permeation, then the permeation amount increases, but the strength of the porous support is reduced
Solution Approach 1:
The invention segments the porous support into two functional layers: a surface layer (thickness 1-10 μm) with high separation performance but lower mechanical strength, and a supporting layer (thickness 10-100 μm) with high porosity (40-60%) and large pore diameter for structural strength and permeation passages. This segmentation allows each layer to optimize for its specific function, resolving the contradiction between permeation productivity and structural strength.
3Area of stationary object
If the thickness of the surface layer is increased to provide more permeation area, then the effective surface area increases, but the number of passages for fluid flow is reduced
Solution Approach 1:
The invention resolves this contradiction by adding a dimensional element through the supporting layer. While the surface layer provides the necessary effective surface area for separation (thickness 1-10 μm), the supporting layer extends in the thickness dimension (10-100 μm) with large pores and high porosity, creating additional permeation pathways in the depth dimension. This multi-dimensional approach allows sufficient surface area for separation while maintaining adequate fluid flow passages through the supporting layer.
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 configuration increases the permeation amount of the separation membrane while maintaining its strength by ensuring a sufficient number of passages for fluid flow and supporting the topmost layer effectively.
Implementation Method 1
the number of passages that enable flow of a component, that has permeated through the separation membrane, from the separation membrane to the surface layer
Data Source
AI summary
A porous support includes a base body, a supporting layer, and a topmost layer. The supporting layer is disposed between the base body and the topmost layer, and makes contact with the topmost layer. A ratio of a porosity of the topmost layer to a porosity of the supporting layer is greater than or equal to 1.08. A ratio of a thickness of the topmost layer to a thickness of the supporting layer is less than or equal to 0.9.