Textured Ion Exchange Membranes for Enhanced Flow Rates

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Solution Overview

Problem

Conventional ion exchange membrane systems have slower ion exchange rates and limited solution treatment flow rates due to smooth, flat membranes, and require thick dielectric spacer layers that increase bulk volume and reduce efficiency, while also being difficult to handle and manufacture.

Innovation Solution

Textured water-splitting membranes with an anion exchange layer abutting a cation exchange layer, featuring a pattern of spaced apart peaks and valleys, and an integral dielectric spacer embedded in a polymer matrix, which increases surface area and reduces the need for separate spacer layers, enhancing ion exchange rates and handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If smooth, flat membranes are used, then membrane manufacturing is simple and handling is easy, but ion exchange rates and solution treatment flow rates are slow

Engineering Contradiction:

Improveion exchange rateVSAvoidmembrane surface structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The membrane surface is modified with a regular pattern of peaks and valleys (curved three-dimensional features) rather than remaining flat. This curvature increases the effective surface area for ion exchange while maintaining manufacturability through embossing or extrusion processes. The peaks and valleys create additional active sites for ion interaction, thereby increasing ion exchange rates without requiring complex assembly structures.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Ease of operation

If thick dielectric spacer layers are used, then membranes are easy to handle and assemble, but cell bulk volume increases and solution treatment output per unit volume decreases

Engineering Contradiction:

Improvemembrane handlingVSAvoidsolution treatment output

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The dielectric spacer function is merged into the membrane structure itself through the integrated texture pattern of peaks and valleys. The spacer material is incorporated within or as part of the membrane assembly, eliminating the need for separate thick spacer layers. This integration maintains membrane handling ease while reducing overall cell volume and increasing solution treatment output per unit volume.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If separate dielectric spacer layers are added between membranes, then current density variation is reduced, but device complexity and manufacturing steps increase

Engineering Contradiction:

Improvecurrent density uniformityVSAvoidnumber of components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The current density control function previously achieved by separate spacer layers is merged into the membrane's integrated texture pattern. The peaks and valleys structure inherently provides uniform spacing and current distribution across the membrane surface, eliminating the need for additional separate spacer components. This reduces device complexity and manufacturing steps while maintaining current density uniformity.

Inventive Principle:

Principle #5Merging (Combining)

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 textured membranes provide improved ion exchange rates, reduced cell volume, and simplified assembly, with increased surface area leading to higher solution treatment flow rates and outputs, while maintaining structural integrity and ease of handling.

Implementation Method 1

The textured membranes provide improved ion exchange rates, reduced cell volume, and simplified assembly, with increased surface area leading to higher solution treatment flow rates and outputs

Methodology Applied

Scientific EffectSurface area effect:

Implementation Method 2

Ion exchange materials include cation and anion exchange materials that contain replaceable ions or which chemically react with specific ions, to exchange cations or anions, respectively, from a solution stream

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Implementation Method 3

When a sufficiently high electric field is applied through the membrane by applying a voltage to the two electrodes, water is irreversibly dissociated or 'split' into component ions H+ and OH- at the boundary between the cation and anion exchange layers

Methodology Applied

Scientific EffectElectrochemical reaction: Electrochemiluminescence

Implementation Method 4

A typical conventional ion exchange cell comprises ion exchange resin beads packed into columns and a stream of solution to be treated is passed through the column

Methodology Applied

Scientific EffectDielectric property: Dielectric

Implementation Method 5

Methodology Applied

Scientific EffectWater splitting: Electrolysis

Data Source

PatentUS7959780B2Textured ion exchange membranes

Publication Date: 2011.06.14 ZHEJIANG LANGKE MEMBRANE MATERIALS TECH CO LTD

AI summary

A textured water-splitting membrane comprises an anion exchange layer abutting a cation exchange layer to form a heterogeneous water-splitting interface therebetween, and a textured surface having a pattern of texture features comprising spaced apart peaks and valleys. The membranes can also have an integral spacer on the membrane. A cartridge can be fabricated with a plurality of the membranes for use in an electrochemical cell. The electrochemical cell can be part of an electrochemical ion exchange system.