Laminated Membrane for Pressure-Resistant Gas Sensors
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Solution Overview
Problem
Standard micro fuel cell sensors attached to devices with dielectric oil are prone to failure due to temperature and pressure variations, which cause damage to thin polymer membranes, especially under negative pressure conditions, leading to sensor flooding and reduced reliability.
Innovation Solution
A micro fuel cell sensor with a laminated gas permeable membrane comprising a polymer film laminated on a porous metal disc, which is impervious to oil and supports the membrane under both positive and negative pressures, allowing gas diffusion while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin polymer membrane is used for gas permeation, then gas diffusion capability is improved, but membrane strength and resistance to pressure variations deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a thin polymer membrane (25-250 microns) laminated onto a porous metallic support disc. The polymer layer provides excellent gas diffusion capability while the rigid porous metal support provides mechanical strength and resistance to pressure variations. This composite structure allows the membrane to withstand both positive pressures (up to 10.3 MPa) and negative pressures without rupture, while maintaining high gas permeability.
2Strength
If a porous metallic disc supports the membrane from the oil side, then membrane strength under positive pressure is improved, but gas circulation is hindered due to oil soaking
Solution Approach 1:
The patent positions the porous metallic support disc on the atmospheric air side of the membrane rather than the oil side. This intermediary placement allows the metal disc to provide mechanical support against positive pressure from the oil side without being in direct contact with the dielectric oil. The polymer membrane acts as the interface between the oil and the supported structure, preventing oil from soaking the porous metal while still allowing gas diffusion through the membrane to reach the electrode.
3Measurement precision
If the membrane is exposed to negative pressure, then sensor responsiveness is maintained, but membrane rupture occurs leading to sensor failure
Solution Approach 1:
The patent provides beforehand cushioning by laminating the thin polymer membrane onto a rigid porous metallic support disc before the sensor is exposed to pressure variations. This pre-established support structure prevents the membrane from collapsing or rupturing when negative pressure (vacuum) conditions occur during transformer maintenance or operation. The metal disc acts as a protective backbone that maintains membrane integrity under tensile stress from negative pressure, preventing oil flooding and sensor failure while allowing the sensor to remain responsive to gas measurements.
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 laminated membrane design enhances sensor reliability by preventing rupture under negative pressures and maintaining gas permeability, reducing sensor failures and ensuring accurate hydrogen measurement in dielectric oil.
Implementation Method 1
polymer membranes that allow dissolved gasses to permeate through, but not the oil the gasses are dissolved in
Implementation Method 2
enabling gas dissolved in oil to diffuse therethrough
Data Source
AI summary
A micro fuel cell sensor having laminated gas permeable membrane. The sensor comprises a housing, first and second gas diffusing electrodes spaced from one another, a fuel-cell spacer having an acidic electrolyte disposed between said first and second electrodes, and two gas permeable membranes. The first gas permeable membrane comprises a polymer laminated on a metal substrate, wherein the substrate comprises pores that have dimensions at least less than one-half the thickness of the polymer film.