SiC Membrane Filter with Low Oxygen Content
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Solution Overview
Problem
Current filter technologies, particularly those using ceramic or non-ceramic membranes, face limitations in filtration performance and lifespan due to the accumulation of particles and energy consumption, especially in tangential filtration systems where recirculation pumps consume significant energy.
Innovation Solution
A filter structure with a membrane made of silicon carbide (SiC) where the membrane separating layer consists of SiC with a low oxygen content, high porosity, and specific pore diameter distribution, treated to reduce residual oxygen, enhancing filtration capacity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ceramic membranes with higher oxygen content are used, then the membrane structure is more stable during sintering, but the filtration performance and lifespan are reduced due to particle accumulation and lower flow rates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the oxygen content in the SiC membrane to be less than 0.5% (compared to conventional membranes with higher oxygen content), and by optimizing the sintering temperature range (1750-1950°C) to achieve the desired balance between membrane stability and filtration performance. This parameter optimization enables high flow rates while maintaining membrane integrity.
2Reliability
If recirculation pumps are used in tangential flow filtration systems, then particle accumulation is limited and stable filtration is achieved, but energy consumption increases significantly
Solution Approach 1:
The patent applies the self-service principle by designing the membrane with optimized porosity (30-70%) and pore diameter distribution that enables the filtration system to maintain stable performance without requiring recirculation pumps. The membrane structure itself facilitates continuous operation with reduced energy input by allowing efficient particle separation through its optimized pore architecture.
3Productivity
If the membrane porosity is increased to improve flow rates, then filtration capacity increases, but the membrane strength and durability may be reduced
Solution Approach 1:
The patent applies composite materials by using silicon carbide (SiC) as the base material with controlled oxygen content, creating a composite structure that achieves both high porosity (30-70%) and high strength. The specific composition of SiC with low oxygen content provides the mechanical integrity needed to maintain membrane strength even at high porosity levels, resolving the trade-off between filtration capacity and durability.
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 SiC membrane filter achieves improved filtration performance and extended lifespan by reducing oxygen content and optimizing pore structure, leading to increased flow rates and reduced energy consumption.
Implementation Method 1
The surface of these channels is usually covered with a membrane, preferably made of a porous inorganic material, referred to herein as a membrane, membrane layer, or membrane separator layer. The membrane's nature and morphology are adapted to retain molecules or particles whose size is close to or greater than the median diameter of the membrane's pores when the filtrate flows through the porous support under the pressure of the fluid passing through the filter.
Implementation Method 2
when the filtrate flows through the porous support under the pressure of the fluid passing through the filter
Data Source
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AI summary
A filter for the filtration of a fluid such as a liquid, comprising or composed of a support element (1) made of a porous ceramic material, said element exhibiting a tubular or parallelepipedal shape delimited by an external surface (2) and comprising, in its internal portion (3), a set of adjacent channels (4) with axes parallel to one another and separated from one another by walls (8) of said porous inorganic material,wherein at least a portion of said channels (4) and/or at least a portion of said external surface are covered with a porous separating membrane layer (5), said filter being characterized in that: - said layer is made of a material essentially composed of sintered grains of silicon carbide (SiC), - the content by weight of elementary oxygen of the layer is less than 0.5%.