Hydrogen Sensor Protective Film Composite Structure

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Solution Overview

Problem

Existing hydrogen sensors using hydrogen-permeable metals as protective films suffer from durability issues due to mechanical stress, diffusion into rare earth metals, and high production costs, limiting their ability to detect high concentrations of hydrogen gas effectively.

Innovation Solution

A hydrogen sensor with a protective film composed of ceramic material and dispersed hydrogen-permeable metal particles, which provides selective hydrogen permeability and mechanical durability, preventing deterioration and reducing the need for expensive metals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a hydrogen-permeable metal film (Pd, Pt) is used as a protective film, then hydrogen selectivity is improved, but durability deteriorates due to mechanical stress and metal diffusion

Engineering Contradiction:

Improvehydrogen selectivityVSAvoiddurability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent uses a composite protective film structure consisting of a rare earth metal oxide base layer and a hydrogen-permeable metal particle-containing layer. This composite structure combines the mechanical stability of the oxide base with the hydrogen selectivity of the metal particles, resolving the contradiction between durability and hydrogen selectivity. The base layer prevents metal diffusion while the particle layer provides selective hydrogen permeation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The protective film incorporates hydrogen-permeable metal particles dispersed in a matrix, creating a porous-like structure that allows selective hydrogen transport. This particle-based approach maintains hydrogen selectivity while the dispersed structure reduces mechanical stress concentration compared to continuous metal films, improving durability.

Inventive Principle:

Principle #31Porous materials

2Measurement precision

If a hydrogen-permeable metal film (Pd, Pt) is used as a protective film, then hydrogen permeability is improved, but production cost increases due to expensive metals

Engineering Contradiction:

Improvehydrogen permeabilityVSAvoidproduction cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

Instead of using a continuous layer of expensive hydrogen-permeable metal, the patent disperses metal particles within the protective film structure. This local quality approach concentrates the expensive metal only where hydrogen permeation is needed (at the particle interfaces), while the bulk of the protective film consists of cheaper rare earth metal oxide, significantly reducing material cost while maintaining hydrogen permeability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite structure combines expensive hydrogen-permeable metal particles with abundant rare earth metal oxide matrix. This composition allows the system to achieve the required hydrogen permeability function using minimal amounts of expensive metal, making the sensor economically viable for practical applications.

Inventive Principle:

Principle #40Composite materials

3Measurement precision

If a hydrogen-permeable metal film is used as a protective film, then hydrogen detection capability is improved, but the sensor can detect only low concentration hydrogen, limiting application scope

Engineering Contradiction:

Improvehydrogen detection capabilityVSAvoidapplication scope

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent adjusts the thickness of the protective film and the concentration of hydrogen-permeable metal particles to optimize hydrogen permeability. By controlling these parameters, the sensor can detect both low concentrations (for leakage warning) and high concentrations (for control applications), expanding the application scope from单一的泄漏检测 to both safety monitoring and process control.

Inventive Principle:

Principle #35Parameter changes

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 sensor achieves high selectivity and durability for hydrogen detection, maintaining hydrogen permeability while resisting non-hydrogen gases and reducing metal diffusion, enabling cost-effective production and detection of both low and high hydrogen concentrations.

Implementation Method 1

the protective film comprises a ceramic material and hydrogen-permeable metal particles dispersed in the ceramic material

Methodology Applied

Scientific EffectHydrogen permeability: Permeation

Implementation Method 2

the change in physical properties of rare earth metal which appears when the rare earth metal is exposed to hydrogen, is utilized for detection of hydrogen

Methodology Applied

Scientific EffectPhysical property change upon hydrogen exposure: Absorption (physical)

Implementation Method 3

hydrogen-permeable metals such as Pd, Pt and the like expand or contract whenever they absorb or release hydrogen

Methodology Applied

Scientific EffectHydrogen absorption and desorption: Absorption (physical)

Data Source

PatentUS7416702B2Hydrogen sensor and process for production thereof

Publication Date: 2008.08.26 MIKUNI CORP

AI summary

According to the present invention there is disclosed a hydrogen sensor comprisinga substrate,a rare earth metal film formed on the substrate, anda protective film formed on the rare earth metal film,wherein the protective film comprises a ceramic material and hydrogen-permeable metal particles dispersed in the ceramic material.