Hydrogen Purifier Membrane Support with Staggered Holes
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Solution Overview
Problem
Existing hydrogen purifiers face challenges in supporting membranes during reverse-pressurization and preventing wrinkling, which can lead to leaks and reduced durability, while also requiring cost-effective and simplified sealing solutions.
Innovation Solution
A hydrogen purifier module design where the membrane is bonded on both sides to a support structure, utilizing a staggered hole pattern in the support screens to prevent wrinkling and enhance durability, with transient liquid-phase bonding for sealing, allowing for both forward and reverse pressurization support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the membrane is supported by a single-sided support structure, then the device complexity is reduced, but the membrane will wrinkle and collapse during reverse-pressurization, reducing reliability
Solution Approach 1:
The support structure is segmented into two separate screens (first support screen and second support screen) positioned on opposite sides of the membrane. This segmentation allows each screen to independently support the membrane during forward and reverse pressurization cycles, preventing wrinkling and collapse while maintaining structural simplicity.
Solution Approach 2:
The dual support screens function as counterbalancing structures that provide opposing support forces. During reverse-pressurization, the second support screen prevents membrane collapse just as the first support screen prevents collapse during forward-pressurization, creating a balanced support system that enhances reliability.
2Productivity
If the membrane is made thinner to improve hydrogen permeability, then the productivity increases, but the membrane becomes more fragile and prone to pinhole leaks, reducing reliability
Solution Approach 1:
The system creates a composite structure by bonding the thin hydrogen-permeable membrane between two support screens. This composite construction allows the use of very thin membranes (2-10 micrometers) for high hydrogen permeability while the support screens provide mechanical strength and prevent pinhole leaks, resolving the contradiction between productivity and reliability.
3Reliability
If the membrane is bonded rigidly to prevent wrinkling, then the membrane durability improves, but the device complexity and sealing difficulty increase
Solution Approach 1:
The support screens are designed with porous structures containing numerous support posts that contact the membrane surface. This porous configuration provides extensive mechanical support to prevent wrinkling during pressurization cycles while maintaining a relatively simple bonding structure through diffusion bonding of the porous screens to the membrane edges.
Solution Approach 2:
The support screens are pre-formed with etched patterns of support posts before being bonded to the membrane. This preliminary preparation of the support structure simplifies the subsequent bonding process and ensures uniform support distribution across the membrane surface, reducing overall device complexity.
4Manufacturing precision
If the purifier operates at high temperature to reduce carbon monoxide coverage, then the hydrogen purity improves, but unwanted intermetallic diffusion between membrane and support occurs, reducing reliability
Solution Approach 1:
The support screens serve as intermediary structures between the membrane and the external environment. By providing mechanical support at the edges and through porous contact points, they reduce the membrane's susceptibility to intermetallic diffusion with sealing materials at high temperatures, enabling operation at 300-700°C for high hydrogen purity while maintaining membrane integrity.
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 design significantly improves membrane durability by preventing wrinkling and maintaining leak-free operation for a higher number of cycles, with the ability to withstand large pressurization swings, thus enhancing the reliability and longevity of the purifier.
Implementation Method 1
hydrogen purifiers utilize a thin, hydrogen-permeable metal membrane to effectively separate hydrogen from a gaseous mixture containing hydrogen
Implementation Method 2
transient liquid-phase bonding for sealing
Data Source
AI summary
A hydrogen purifier utilizing a hydrogen-permeable membrane to purify hydrogen from mixed gases containing hydrogen is disclosed. Improved mechanical support for the permeable membrane is described, enabling forward or reverse differential pressurization of the membrane, which further stabilizes the membrane from wrinkling upon hydrogen uptake.