Zeolite Membrane Manufacturing via Solubility Parameter Masking
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Solution Overview
Problem
Existing zeolite membrane manufacturing methods face challenges in achieving a balance between separation performance and permeance, with difficulties in depth control of impregnation and uniformity, leading to increased production costs and complex operations.
Innovation Solution
A method involving the formation of a surface layer with a low polar polymer on a porous substrate, followed by impregnation with a high polar masking polymer and subsequent removal of the surface layer to control impregnation depth, allowing for the growth of a zeolite membrane with improved permeation properties and separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin zeolite membrane is manufactured to improve permeation property, then permeance is enhanced, but separation factor decreases
Solution Approach 1:
The patent applies parameter changes by controlling the solubility parameter difference between the masking polymer and low polar polymer to achieve optimal impregnation depth. By selecting a masking polymer with specific solubility parameter (SP value) that is 1.0 (cal/cm³)¹/² or more different from the low polar polymer, the patent achieves uniform membrane thickness while maintaining both high permeance and separation factor, thus resolving the contradiction between permeation property and separation performance.
2Manufacturing precision
If depth control of impregnation is improved to achieve uniform membrane, then manufacturing precision increases, but device complexity increases
Solution Approach 1:
The patent simplifies the manufacturing process by using solubility parameter matching as a controlling parameter. Instead of complex depth control mechanisms, the patent selects a masking polymer whose solubility parameter differs by 1.0 (cal/cm³)¹/² or more from the low polar polymer, enabling automatic depth control during impregnation. This approach achieves uniform membrane formation without adding complex process steps or equipment.
3Manufacturing precision
If a preliminary impregnation masking layer is used to control impregnation depth, then manufacturing precision improves, but loss of time increases
Solution Approach 1:
The patent addresses the time consumption issue by selecting a masking polymer with specific solubility characteristics that enable rapid removal. By choosing a masking polymer whose solubility parameter is 1.0 (cal/cm³)¹/² or more different from the low polar polymer, the patent ensures that the masking layer can be quickly removed during the membrane formation process, significantly reducing the one-week removal time associated with conventional PMMA-based masking layers.
4Ease of operation
If a cation polymer is applied to remove electric charge before seed crystal application, then ease of operation improves, but device complexity increases
Solution Approach 1:
The patent eliminates the need for the cation polymer treatment step by directly using the high polar polymer as the masking polymer. This extraction of the unnecessary intermediate step (removing electric charge with cation polymer) simplifies the process while maintaining the ability to uniformly apply seed crystals, as the high polar polymer itself provides the necessary surface properties for seed crystal attachment.
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 results in a thinner zeolite membrane with enhanced permeation properties and separation performance, specifically achieving a CO2/CH4 separation factor of 10 or more and CO2 gas permeance of 5×10−7 mol/s/m2/Pa or more, while reducing production complexity and time.
Implementation Method 1
a surface layer for covering the surface is formed on the first surface of the porous substrate by attaching a low polar polymer having a solubility parameter (SP value) of 8.0 (cal/cm3)1/2 or less
Implementation Method 2
the porous substrate is impregnated with a high polar polymer having low compatibility with the low polar polymer as the masking polymer, and then the surface layer is removed
Implementation Method 3
a high polar polymer having low compatibility with the low polar polymer and a SP value of above 8.0 (cal/cm3)1/2
Implementation Method 4
a seed crystal attaching step for attaching a seed crystal functioning as a seed for forming a zeolite membrane on the first surface of the porous substrate where the surface layer has been removed
Implementation Method 5
a removing step for removing the structure directing agent from the dense zeolite membrane and removing the masking polymer from the porous substrate
Data Source
AI summary
There is provided a zeolite membrane which is thinner than a conventional membrane and which has improved permeability and a method for manufacturing the zeolite membrane. The method includes a surface layer forming step for forming a surface layer by attaching a low polar polymer on a first surface of a porous substrate to cover the surface, a filling step for filling a masking polymer into pores in the porous substrate from a surface different from the first surface of the porous substrate up to the surface layer by impregnating the porous substrate with the masking polymer and solidifying the masking polymer, and a surface layer removing step for removing the surface layer. After the surface layer removing step, a zeolite membrane is formed on the first surface of the porous substrate.