Two-Layer Membrane with Tiny, Ordered Pores for Carbon Capture

This patent describes a two-layer filter, called a mixed matrix membrane, that uses a support layer with precisely arranged, uniform tiny holes and a carbon dioxide capture layer to trap CO2.

What it covers

This patent describes a carbon capture mixed matrix membrane designed to separate carbon dioxide from other gases. It features a "polymeric support layer" (Claim 1) that is 50-500 micrometers thick and contains "spatially ordered uniform sized pores" (Claim 1), meaning the tiny holes are arranged in a precise, consistent pattern. These pores can range from 100 nanometers to 100 micrometers in diameter (Claim 5). On or within this support layer is a "carbon dioxide capture layer" (Claim 1), which uses solid porous materials with specific "carbon dioxide adsorption sites" (Claim 1) to attract and hold CO2 molecules. These capture materials can include amine-functionalised substances or metal-organic frameworks like ZIF-8 (Claim 8). For example, exhaust gas from a factory could pass through this membrane, with the capture layer selectively binding the CO2 while allowing other gases to pass through.

What it doesn't cover

• —Does not cover membranes where the polymeric support layer has randomly sized or arranged pores, as it specifies "spatially ordered uniform sized pores" (Claim 1).
• —Does not cover membranes with a support layer made of non-polymeric materials, as it explicitly claims a "polymeric support layer" (Claim 1).
• —Does not cover general gas separation membranes that are not specifically designed with "at least one carbon dioxide adsorption site" (Claim 1).
• —Does not cover membranes where the polymeric support layer is thinner than 50 micrometers or thicker than 500 micrometers (Claim 1).
• —Does not cover membranes that are purely polymeric or purely inorganic, as it specifies a "mixed matrix membrane" (Claim 1) combining polymer and solid porous material.

The clever bit

The truly novel aspect is the "spatially ordered uniform sized pores" in the polymeric support layer. This precise patterning helps ensure consistent gas flow and optimal integration of the CO2 capture material, leading to a more efficient and stable membrane.

Why it matters

Carbon capture technology is crucial for reducing greenhouse gas emissions from industrial sources and power generation, helping to address climate change. Membranes offer a potentially energy-efficient and scalable method for separating CO2. This patent contributes to advancing membrane design by focusing on the precise structural control of the support layer, which can improve the overall efficiency and durability of carbon capture systems.

Real-world examples

• 1.Industrial carbon capture facilities
• 2.Power plant emissions control systems
• 3.Direct air capture (DAC) systems
• 4.Gas separation units in chemical processing