Hybrid Ceramic Membrane Densification for Low Gas Crossover
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Solution Overview
Problem
Existing ceramic membranes used in alkaline water electrolysis lack durability and stability under harsh conditions, leading to hydrogen gas crossover and limited operating temperatures, necessitating a scalable method for a self-standing, mechanically robust hybrid ceramic membrane with controlled pore size.
Innovation Solution
A method involving the combination of TiO2 nanoparticles, metal oxide nanoparticles, and a curable polymer resin to create a dense composite polymeric-ceramic membrane, where the ceramic support layer is coated with TiO2 and further densified with ion-conducting polymers, using techniques like in situ polymerization and impregnation to fill pores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If porous ceramic membranes are used to provide mechanical strength, then mechanical stability is improved, but gas crossover increases and separation performance deteriorates
Solution Approach 1:
The patent employs a nested structure where a dense polymer layer is embedded within the porous ceramic membrane matrix. The polymer fills the pores of the ceramic support, creating a hierarchical structure that maintains mechanical strength from the ceramic while achieving gas separation functionality from the dense polymer phase. This nested arrangement allows the weaker polymer phase to be protected and supported by the rigid ceramic framework.
Solution Approach 2:
The invention creates a composite membrane system combining ceramic and polymer materials with complementary properties. The ceramic phase (e.g., alumina, zirconia) provides mechanical strength, chemical stability, and thermal resistance, while the polymer phase (e.g., PTFE, PVDF) provides dense separation characteristics and low gas permeability. The synergistic combination resolves the contradiction between mechanical stability and gas crossover prevention.
2Ease of manufacture
If polymer content is increased to improve processability, then ease of manufacture is improved, but mechanical strength and chemical stability deteriorate
Solution Approach 1:
The patent applies local quality by concentrating the polymer phase specifically within the pore spaces of the ceramic membrane, rather than uniformly distributing it throughout the entire membrane structure. This localized placement allows the polymer to provide processing benefits and separation functionality only where needed (in the pores), while the ceramic matrix maintains overall structural integrity and mechanical strength in the bulk material.
3Object-affected harmful factors
If pore size is reduced to prevent gas diffusion, then gas crossover is reduced, but ionic conductivity decreases
Solution Approach 1:
The invention utilizes porous materials with a dual-function design: the ceramic phase maintains a porous structure optimized for ionic transport (with appropriate pore size, connectivity, and surface chemistry for OH- ion conduction), while the polymer phase forms a separate dense network within the pores that blocks gas diffusion pathways. This allows the membrane to simultaneously achieve low gas crossover and high ionic conductivity through spatially differentiated pore utilization.
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 resulting membrane exhibits improved mechanical stability, reduced gas crossover, and maintains ionic conductivity, enabling long-term stability and performance in electrochemical applications.
Implementation Method 1
combining TiO2 nanoparticles, at least another metal oxide nanoparticle and a curable polymer resin to create a mixture; curing the mixture to obtain a first composite material
Implementation Method 2
heating the first composite material to a first temperature for removing the polymer from said first composite material
Implementation Method 3
heating the second composite material to a second temperature for sintering the TiO2 nanoparticles, and the at least another metal oxide nanoparticles, thereby creating the ceramic porous support layer
Implementation Method 4
coating said ceramic porous support layer with a TiO2 suspension to obtain a TiO2-coated ceramic porous support layer
Implementation Method 5
polymer filling pores of the TiO2-coated ceramic porous support layer to obtain the dense composite polymeric-ceramic material
Data Source
AI summary
The present invention relates to a method of manufacturing a dense composite polymeric-ceramic membrane, compromising the steps of casting a porous ceramic support layer comprising YSZ and TiO2 flakes, followed by thermal curing and sintering steps, coating the prepared porous ceramic support structure with a thin layer of TiO2 to vary the pore size distribution of the support structure and further densification by using ion selective polymers to reduce gas crossover while maintaining a high enough conductivity.