Hydrogen-Permeable Membrane with Ceramic Matrix
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Solution Overview
Problem
Current hydrogen-permeable membranes using palladium are expensive, have low mechanical strength, and are limited in thickness due to durability issues caused by hydrogen reactions, failing to balance performance, durability, and cost effectively.
Innovation Solution
A hydrogen-permeable membrane composed of ceramic materials like aluminum or silicon nitrides/oxides with dispersed hydrogen-permeable metal particles such as palladium, niobium, or their alloys, formed on a porous ceramic substrate with a thickness of 5 to 1,000 nm, utilizing vapor-phase growth or sputtering for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If palladium is used as hydrogen-permeable membrane material, then hydrogen permeability is improved, but cost increases and mechanical strength decreases
Solution Approach 1:
The patent uses a composite structure combining palladium metal particles dispersed in a ceramic matrix (alumina, silica, or nitrogen-containing ceramic). This composite approach maintains hydrogen permeability through the palladium particles while the ceramic matrix provides mechanical strength and structural support, resolving the contradiction between permeability and strength.
Solution Approach 2:
The patent applies local quality by having palladium particles distributed throughout the ceramic matrix rather than using continuous palladium layer. The hydrogen permeation function is localized to the palladium particles, while the ceramic matrix provides mechanical properties, allowing optimization of each component for its specific function.
2Strength
If palladium membrane thickness is increased to improve mechanical strength, then strength is improved, but cost increases and durability decreases due to hydrogen reaction
Solution Approach 1:
The ceramic matrix serves as a protective barrier that isolates the palladium particles from direct contact with hydrogen, preventing the hydrogen reaction that causes powdering and deterioration. This allows thin palladium layers to maintain both strength and durability.
Solution Approach 2:
The ceramic matrix acts as an intermediary between the palladium particles and the hydrogen environment. It provides mechanical support and protects the palladium from hydrogen exposure, enabling thin membrane thickness while maintaining durability.
3Ease of manufacture
If substitute materials for palladium are used to reduce cost, then cost is reduced, but hydrogen permeability decreases and durability worsens due to hydrogen reaction
Solution Approach 1:
The patent uses small palladium particles dispersed in a ceramic matrix, so that only a small amount of expensive palladium is needed to achieve sufficient hydrogen permeability. The ceramic matrix provides the bulk structure at low cost, reducing overall material cost while maintaining permeability through the distributed palladium particles.
4Ease of manufacture
If membrane thickness is reduced to lower cost, then cost is reduced, but mechanical strength decreases
Solution Approach 1:
The ceramic matrix provides the mechanical strength and structural support for thin membrane sections, while the dispersed palladium particles maintain hydrogen permeability. This composite structure enables thin membrane thickness (reducing cost) while preserving mechanical strength through the ceramic framework.
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 membrane achieves high hydrogen permeability, durability, and low cost by dispersing metal particles uniformly in a ceramic matrix, reducing thickness and mechanical stress, while maintaining selectivity for hydrogen over other gases.
Implementation Method 1
a hydrogen-permeable membrane which can selectively pass hydrogen contained in, for example, the fuel hydrogen flowing through the inside of fuel cell
Implementation Method 2
forming a hydrogen-permeable membrane according to any of [1] to [3], on at least one side of a porous ceramic substrate by vapor-phase growth or sputtering
Implementation Method 3
forming a hydrogen-permeable membrane according to any of [1] to [3], on at least one side of a porous ceramic substrate by vapor-phase growth or sputtering
Data Source
AI summary
According to the present invention there is disclosed a hydrogen-permeable membrane which comprisesa ceramic material composed of a nitride of aluminum (Al) and/or silicon (Si), an oxide of aluminum (Al) and/or silicon (Si), or a silicide of a rare earth element, andparticles of at least one kind of hydrogen-permeable metal selected from palladium (Pd), niobium (Nb), vanadium (V), tantalum (Ta) and an alloy thereof, dispersed in the ceramic material,wherein a proportion of the hydrogen-permeable metal particles in the hydrogen-permeable membrane is 30 to 70% by mass and a thickness of the membrane is 5 to 1,000 nm.