Leak-Proof Membrane Element Segmentation
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Solution Overview
Problem
Current gas separation and cleaning technologies using palladium alloy membranes are inefficient due to thick membrane thickness, leading to high costs and slow hydrogen flux, which is a limitation in large-scale energy production and hydrogen fuel station applications.
Innovation Solution
A leak-proof membrane element is created by depositing a thin metal foil, typically 1-5 micrometers thick, onto a porous substrate using methods like physical deposition, with overlapping joints welded by diffusion bonding without specialized apparatus, and utilizing the metal foil as a gasket for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick palladium alloy pipes are used for gas separation, then the membrane structure is stable and leak-proof, but the hydrogen flux is slow and material costs are high
Solution Approach 1:
The membrane system is segmented into two functional parts: a thin selective metal membrane layer (providing separation functionality) and a thick porous supporting substrate (providing mechanical stability). This segmentation allows each layer to be optimized independently - the metal layer can be made extremely thin (1-10 micrometers) to maximize hydrogen flux while the substrate provides the necessary structural support and leak-proof properties.
2Reliability
If thick palladium alloy pipes are used, then the membrane is leak-proof, but the material costs are high
Solution Approach 1:
The membrane is segmented into a thin selective metal layer and a thick porous substrate. The metal layer thickness is reduced to 1-10 micrometers, dramatically reducing the quantity of expensive palladium material required while maintaining the leak-proof selective separation function. The substrate, made of cheaper materials like stainless steel, ceramic, or polymer, provides the bulk structural support.
Solution Approach 2:
The invention uses an extremely thin metal film (1-10 micrometers) as the selective membrane layer deposited on the substrate. This thin film approach minimizes material usage of expensive metals like palladium while maintaining the essential gas separation and leak-proof properties through the film's selective permeability characteristics.
3Productivity
If the metal coating thickness is reduced to increase hydrogen flux, then the hydrogen flux increases, but the coating becomes insufficiently stable and leak-proof
Solution Approach 1:
The membrane function is segmented between a thin selective metal layer (1-10 micrometers) that provides high hydrogen flux and a thick porous substrate (millimeters to centimeters) that provides mechanical stability and structural support. This segmentation resolves the contradiction by allowing the metal layer to be thin for high flux while the substrate ensures stability and leak-proof properties.
Solution Approach 2:
A porous supporting substrate is used to provide mechanical strength and structural stability to the thin metal membrane. The porous structure allows gas permeation while the substrate's thickness and porosity control provide the necessary stability, enabling the metal coating to be made extremely thin (1-10 micrometers) without compromising overall membrane reliability.
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
This approach increases hydrogen flux while reducing material costs and maintaining a stable, leak-proof structure, achieving high selectivity and efficiency in gas separation, as demonstrated by a hydrogen flux of 2.5 × 10^-6 mbar/(m²*s*Pa) with selectivity better than 1000 at 25 bar absolute differential pressure.
Implementation Method 1
a metal foil (membrane) or such metal foil having a thickness of less than 10 micrometers, and being selectively permeable for specific gases
Implementation Method 2
a material that is penetrable for the desired gases by solid phase diffusion (e.g. mixed conductors of electronic and oxygen ion conducting and/or proton conducting ceramics or metals of the IVB and VB groups)
Implementation Method 3
joining by diffusion bonding the overlapping joints (8) to a continuous, non-porous membrane layer
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A leak-proof membrane element (1) for the selective separation or cleaning of gas, wherein a metal foil (membrane) (3) is deposited onto a supporting stock (substrate) (2, 20) having connection means (4, 21, 34) on the ends/edges of the substrate allowing the membrane element to be installed in a housing. A metal foil (3), having a thickness of less that 10 micrometers and being selectively permeable for specific gases, is arranged in flakes or wound with overlapping joints (8) on the outside of the substrate (2, 20), any joints being welded together by diffusion bonding so that the foil forms a continuous, leak-proof metal membrane layer. The substrate being made of a material (metal, ceram, polymer, or combinations thereof) exhibiting a very high gas flux for the gas(es) that the membrane is to let through.