Patent ID: 7959711

Claim:
A method of making a gas separation membrane, wherein said method comprises: applying to a surface of a porous substrate a layer of a nanopowder, comprising nanoparticles of a gas-selective metal, to provide a surface treated porous substrate, wherein the method employed to apply said layer of nanopowder to the surface of said porous substrate comprises the steps of: aerosolizing a suspension of nanoparticles of the gas-selective metal within a liquid solvent, combining a flow stream of the thus-formed aerosol with an annular sheath gas flow, passing the thus-combined aerosol and flow stream through an extended nozzle, and focusing the thus-combined aerosol and flow stream upon the surface of the porous substrate to thereby apply a layer of nanoparticles of a gas-selective material to the surface of said porous substrate, said layer having a thickness of from 3 nm (0.003 μm) to 15 μm; and heating said surface treated porous substrate at a temperature maintained below the melting temperature of said porous substrate but sufficient to sinter said layer of nanopowder to provide a heat treated surface treated porous substrate with a sintered layer of gas tight, gas-selective nanopowder suitable for use as a gas separation membrane.