Zeolite Membrane Complex With Low-Density Grain Boundary Phase

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Solution Overview

Problem

Zeolite membranes used for molecular separation and adsorption require high permeability, high separating performance, and durability, but existing research has not addressed the influence of the grain boundary phase on durability.

Innovation Solution

A zeolite membrane complex with a porous support and a zeolite membrane having a zeolite crystal phase and a dense grain boundary phase, where the grain boundary phase has a density smaller than the zeolite crystal phase and a width of 2 nm to 10 nm, is produced using hydrothermal synthesis, with the grain boundary phase being constituted by an inorganic substance and containing an amorphous substance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a zeolite membrane is formed with conventional grain boundary phase (density larger than zeolite crystals), then the membrane structure is stable, but the durability decreases due to corrosion from permeant substances

Engineering Contradiction:

ImprovedurabilityVSAvoidcorrosion from permeant substances

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the density parameter of the grain boundary phase from being larger than zeolite crystal density to being smaller than zeolite crystal density. This parameter inversion creates a low-density grain boundary phase that is more resistant to corrosion from permeant substances, thereby improving durability while maintaining membrane stability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite grain boundary phase comprising multiple components including inorganic substances and amorphous substances. This composite structure provides both mechanical stability and chemical resistance to corrosion, resolving the contradiction between stability and durability

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If the grain boundary phase width is reduced to improve separating performance, then the molecular sieving action is enhanced, but the permeability may be affected

Engineering Contradiction:

Improveseparating performanceVSAvoidpermeability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent optimizes the width parameter of the grain boundary phase to a specific range (2 nm to 10 nm). This controlled width provides sufficient molecular sieving capability for high separating performance while maintaining adequate permeability by preventing excessive restriction of molecular transport

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates different density regions within the grain boundary phase, with a low-density region closer to the zeolite crystals and a higher-density region farther away. This local quality variation allows the grain boundary to provide both separation functionality and permeability by having different properties at different locations

Inventive Principle:

Principle #3Local quality

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 configuration enhances the permeability, separating performance, and durability of the zeolite membrane by reducing the contact of permeant substances with the grain boundary phase, thereby improving corrosion resistance and maintaining high separating performance over time.

Implementation Method 1

separation of specific molecules and adsorption of molecules through a molecular sieving action of zeolite

Methodology Applied

Scientific EffectMolecular sieving: Molecular Sieve

Implementation Method 2

adsorption of molecules through a molecular sieving action of zeolite

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 3

raw materials of a zeolite membrane are divided into two liquids, the raw material liquids are introduced into pores of a porous body from two sides so that a boundary between the two liquids is formed in the pores, and a zeolite membrane is formed in the pores through hydrothermal synthesis

Methodology Applied

Scientific EffectHydrothermal synthesis:

Data Source

PatentUS11498035B2Zeolite membrane complex, method for producing zeolite membrane complex, and separation method

Publication Date: 2022.11.15 NGK INSULATORS LTD

AI summary

A zeolite membrane complex includes a porous support, and a zeolite membrane formed on the support. The zeolite membrane includes a zeolite crystal phase constituted by a plurality of zeolite crystals, and a dense grain boundary phase, which is a region between the plurality of zeolite crystals. A density of at least part of the grain boundary phase is smaller than a density of the zeolite crystal phase. A width of the grain boundary phase is 2 nm or more and 10 nm or less. Accordingly, it is possible to realize high permeability and high separating performance, and high durability of the zeolite membrane.