Separation Membrane Transfer via Adhesive Strength Ratio
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Solution Overview
Problem
Conventional methods for manufacturing separation membranes face challenges in transferring the separation functional layer and intermediate layer from a release liner to a porous support member due to dissolution issues with solvents and poor peeling efficiency, leading to decreased permeation rates.
Innovation Solution
A method involving applying a coating liquid containing the intermediate layer material onto a laminate with a release liner and separation functional layer, drying, and then bonding this laminate to a porous support member, ensuring a high adhesive strength ratio between the intermediate layer and support member to facilitate easy removal of the release liner, while using a silicone-based pressure-sensitive adhesive for the intermediate layer with a storage elastic modulus of 1.0×105 Pa or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coating liquid containing a material of the separation functional layer is applied onto an intermediate layer and porous support member, then the separation functional layer can be formed, but the intermediate layer and porous support member tend to be dissolved by the solvent in the coating liquid
Solution Approach 1:
The patent applies a protective coating onto the intermediate layer and porous support member before applying the coating liquid for the separation functional layer. This protective coating acts as a barrier that prevents the solvent in the coating liquid from dissolving the intermediate layer and porous support member, thereby resolving the contradiction between forming the separation functional layer and preventing dissolution of underlying layers.
2Ease of manufacture
If the intermediate layer is dissolved, then the coating liquid comes in contact with the porous support member, but the permeation rate of permeated fluid from the separation membrane decreases significantly
Solution Approach 1:
The protective coating is applied in advance to prevent dissolution of the intermediate layer, thereby maintaining the integrity of the porous support member and preserving the high permeation rate of the final membrane product.
3Adaptability or versatility
If conventional techniques are used to transfer the separation functional layer and intermediate layer from a release liner, then peeling off the release liner becomes difficult
Solution Approach 1:
The patent introduces a release liner with specific local properties (low adhesion to the intermediate layer) that enables easy peeling. The release liner is designed to have different adhesive characteristics: it adheres sufficiently to allow handling and transfer, but releases easily when needed, resolving the contradiction between transfer capability and ease of peeling.
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 enables successful transfer of the separation functional layer and intermediate layer to the porous support member, enhancing the permeation rate and separation efficiency of acid gases like carbon dioxide without compromising the adhesive strength, thus overcoming previous dissolution and peeling issues.
Implementation Method 1
drying the obtained coating film
Implementation Method 2
bonding the intermediate layer of a second laminate having the release liner, the separation functional layer, and the intermediate layer in this order to the porous support member
Data Source
AI summary
The present invention provides a method for manufacturing a separation membrane suitable for transferring a separation functional layer and an intermediate layer from a release liner to a porous support member. The manufacturing method of the present invention is a method for manufacturing a separation membrane 10 including a separation functional layer 1, a porous support member 3, and an intermediate layer 2. The manufacturing method includes: forming the intermediate layer 2 on a first laminate 15 having a release liner 5 and the separation functional layer 1; bonding the intermediate layer 2 of a second laminate 16 having the release liner 5, the separation functional layer 1, and the intermediate layer 2 in this order to the porous support member 3 and thereby forming a third laminate 17; and removing the release liner 5 from the third laminate 17. In the manufacturing method, the intermediate layer 2 is formed in such a manner that a ratio R of an adhesive strength A2 (N/50 mm) between the intermediate layer 2 and the porous support member 3 with respect to an adhesive strength A1 (N/50 mm) between the release liner 5 and the separation functional layer 1 is 3.1 or more.