Silica Membrane Drying via Controlled Air Dew Point
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Solution Overview
Problem
Existing methods for manufacturing silica membranes struggle to achieve high separation performance and permeation flux simultaneously, with increased coating repetitions leading to deteriorated permeation flux and prior methods resulting in membranes with defects and unsatisfactory separation factors.
Innovation Solution
Drying a silica sol on a porous substrate using air with a dew point of -70 to 0°C and an air velocity of 5 to 20 m/sec to prevent defects and enhance separation performance, allowing for a thinner, high-performance silica membrane with reduced coating requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of coating repetitions is increased to obtain a membrane with higher separation factor, then separation performance is improved, but permeation flux deteriorates
Solution Approach 1:
The patent changes the drying parameters by controlling air temperature (20-80°C) and humidity (dew point -70 to 0°C) to achieve optimal membrane formation. This allows obtaining high separation performance with fewer coating repetitions, thereby maintaining high permeation flux
Solution Approach 2:
The patent applies preliminary action by optimizing the drying conditions before membrane formation is completed. By controlling the drying environment in advance with specific temperature and humidity parameters, the membrane achieves better separation performance in fewer coating steps
2Ease of manufacture
If conventional drying methods are used to manufacture silica membrane, then manufacturing process is simple, but membrane contains defects and separation factor is insufficient
Solution Approach 1:
The patent modifies the drying parameters by controlling air temperature (20-80°C) and humidity (dew point -70 to 0°C) to eliminate membrane defects and achieve high separation factors, while maintaining the simplicity of the manufacturing process
3Productivity
If air blowing is used to dry silica sol, then drying speed is improved, but membrane thickness uniformity deteriorates
Solution Approach 1:
The patent optimizes the air blowing parameters by controlling temperature (20-80°C) and humidity (dew point -70 to 0°C) to achieve both high drying speed and uniform membrane thickness, resolving the contradiction between drying speed and thickness uniformity
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 method achieves a silica membrane with high separation performance and permeation flux at reduced costs by minimizing defects and optimizing membrane thickness, while maintaining cost-effectiveness.
Implementation Method 1
drying the silica sol by air blowing having a dew point of -70 to 0°C
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A simple method of manufacturing a silica membrane which has high separation performance and high permeation flux is provided. The method is a method for manufacturing a silica membrane 1 by depositing a silica sol on a porous substrate 11, drying the silica sol by air blowing which has a dew point of -70 to 0°C, and then firing the same thereafter to produce the silica membrane 1. Further, the silica sol is preferably dried by air blowing at an air velocity of 5 to 20 m/sec.