Silicon Carbide Porous Membrane Emulsification Flux
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Solution Overview
Problem
Current porous glass membranes used in emulsification processes suffer from low dispersed-phase flux and high costs due to high hydraulic resistance and expensive raw materials, limiting their efficiency and affordability.
Innovation Solution
A porous membrane is manufactured by mixing silicon carbide powders with a coagulant and a sintering aid, then sintering the mixture to create a silicon-carbide-based membrane with optimized pore structure, reducing hydraulic resistance and cost while enhancing dispersed-phase flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If porous glass membranes are used for membrane emulsification, then the emulsification process can be achieved, but the dispersed-phase flux is low due to high hydraulic resistance
Solution Approach 1:
The patent uses porous silicon carbide membranes with optimized pore structures to achieve high dispersed-phase flux while maintaining mechanical strength. The porous structure reduces hydraulic resistance compared to traditional porous glass membranes, directly resolving the contradiction between productivity and harmful factors.
Solution Approach 2:
The patent optimizes pore size, pore distribution, and membrane thickness parameters of the silicon carbide membrane to minimize hydraulic resistance while maintaining structural integrity. By changing these physical parameters, the membrane achieves high flux without sacrificing strength, resolving the contradiction between productivity and harmful factors.
2Reliability
If porous glass membranes are used for membrane emulsification, then the emulsification process can be achieved, but the cost is high due to expensive raw materials
Solution Approach 1:
The patent replaces expensive porous glass membranes with silicon carbide membranes that can be manufactured at lower cost using more abundant raw materials. The silicon carbide membrane maintains reliable emulsification performance while significantly reducing manufacturing costs, directly resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent uses composite silicon carbide-based materials that combine the benefits of ceramic stability with cost-effective manufacturing. The composite material structure maintains the necessary mechanical and chemical properties for reliable emulsification while reducing dependence on expensive glass raw materials, resolving the contradiction between reliability and ease of manufacture.
3Productivity
If asymmetric structure is introduced to reduce hydraulic resistance, then dispersed-phase flux improves, but the raw material becomes harder to acquire and cost increases
Solution Approach 1:
The patent employs porous silicon carbide materials that can be manufactured with asymmetric pore structures using readily available raw materials. The porous silicon carbide provides the necessary asymmetric structure for high flux while being more accessible and cheaper than the specialized glass materials previously required, resolving the contradiction between productivity and ease of manufacture.
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 resulting membrane achieves high dispersed-phase flux, stability, reduced scale formation, lower costs, extended service life, and ease of availability, improving the emulsification process.
Implementation Method 1
sintering the compressed second mixture
Implementation Method 2
adding a coagulant to silicon carbide powders
Data Source
AI summary
A method for manufacturing a porous membrane includes: mixing silicon carbide powders and a coagulant to form a first mixture; adding a sintering aid to the first mixture to form a second mixture; compressing the second mixture; and sintering the compressed second mixture. More particularly, the coagulant is in an amount of 1% to 3% by weight of the silicon carbide powders and the sintering aid is in an amount of 10% by weight of the first mixture.