Hydrogen separation filter and method for manufacturing hydrogen separation filter

Patent metadata

Field	Value
Publication number	US-12371321-B2
Application number	US-202217973929-A
Country	US
Kind code	B2
Filing date	Oct 26, 2022
Priority date	Nov 19, 2021
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

Abstract

Provided is a hydrogen separation filter allowing a hydrogen purification at a lower temperature than conventional one, and a method for manufacturing the same. A hydrogen separation filter includes a porous substrate, a lattice expansion layer formed on the porous substrate and containing a first material, and a hydrogen dissociation and transmission layer formed on the lattice expansion layer and containing a second material selected from the group consisting of Pd, V, Ta, Ti, Nb, and alloys thereof. The first material and the second material have a same crystalline structure. A lattice constant a 1, bulk of a first bulk material having a same composition and a same crystalline structure as the first material and a lattice constant a 2, bulk of a second bulk material having a same composition and a same crystalline structure as the second material satisfy a formula (1):

1.03 a 2, bulk ≤a 1, bulk ≤1.15 a 2, bulk   (1).

First claim

What is claimed is:

1. A hydrogen separation filter comprising:
a porous substrate;
a lattice expansion layer formed on the porous substrate, the lattice expansion layer containing a first material; and
a hydrogen dissociation and transmission layer formed on the lattice expansion layer, the hydrogen dissociation and transmission layer containing a second material selected from the group consisting of Pd, V, Ta, Ti, Nb, and alloys thereof,
wherein the first material and the second material have a same crystalline structure, and
wherein a lattice constant a 1, bulk of a first bulk material having a same composition and a same crystalline structure as the first material and a lattice constant a 2, bulk of a second bulk material having a same composition and a same crystalline structure as the second material satisfy a formula (1):
1.03 a 2, bulk ≤a 1, bulk ≤1.15 a 2, bulk   (1).

2. The hydrogen separation filter according to claim 1 ,
wherein the second material has a lattice constant a 2 satisfying a formula (2):
a 2, bulk <a 2   (2),

the lattice constant a 2 being obtained from a lattice spacing between crystal planes perpendicular to an interface between the lattice expansion layer and the hydrogen dissociation and transmission layer.

3. The hydrogen separation filter according to claim 1 ,
wherein the second material has a lattice constant a 2 satisfying a formula (3):
1.5≤[( a 2 −a 2, bulk )/ a 2, bulk ]×100≤3.6  (3),

the lattice constant a 2 being obtained from a lattice spacing between crystal planes perpendicular to an interface between the lattice expansion layer and the hydrogen dissociation and transmission layer.

4. The hydrogen separation filter according to claim 1 ,
wherein a lattice constant a 2, interface of the second material in an interface between the lattice expansion layer and the hydrogen dissociation and transmission layer and a lattice constant a 2, surface of the second material in a surface of the hydrogen dissociation and transmission layer satisfy a formula (4):
0.98≤ a 2, surface /a 2, interface ≤1  (4),

the lattice constant a 2, interface being obtained from a lattice spacing between crystal planes perpendicular to the interface, and the lattice constant a 2, surface being obtained from a lattice spacing between crystal planes perpendicular to the interface.

5. The hydrogen separation filter according to claim 1 ,
wherein the hydrogen dissociation and transmission layer has a thickness in a range of 10 nm to 350 nm.

6. The hydrogen separation filter according to claim 1 ,
wherein the first material is Ag, Au, or Al, and
wherein the second material is Pd.

7. The hydrogen separation filter according to claim 6 ,
wherein the first material is Ag.

8. The hydrogen separation filter according to claim 1 ,
wherein the lattice expansion layer and the hydrogen dissociation and transmission layer have a total thickness exceeding seven times of a pore diameter of the porous substrate.

9. The hydrogen separation filter according to claim 1 , further comprising
a hydrogen release layer containing a third material and formed between the porous substrate and the lattice expansion layer,
wherein the third material has a binding energy with hydrogen in a range of 230 kJ/mol H to 270 kJ/mol H.

10. The hydrogen separation filter according to claim 9 ,
wherein the third material has a same crystalline structure as the first material and the second material.

11. The hydrogen separation filter according to claim 10 ,
wherein a lattice constant a 3, bulk of a third bulk material having a same composition and a same crystalline structure as the third material satisfies a formula (5):
0.8 a 1, bulk ≤a 3, bulk ≤1.0 a 1, bulk   (5).

12. The hydrogen separation filter according to claim 9 ,
wherein the first material is Ag,
wherein the second material is Pd, and
wherein the third material is Cu or Ni.

13. The hydrogen separation filter according to claim 9 ,
wherein the first material is Nb, W, or Mo,
wherein the second material is V, and
wherein the third material is Fe.

14. A method for manufacturing the hydrogen separation filter according to claim 1 , the method comprising depositing the first material and the second material sequentially on the porous substrate with an evaporation method under a pressure in a range of 1×10 −6 Pa to 1×10 −4 Pa.

15. A method for manufacturing the hydrogen separation filter according to claim 9 , the method comprising:
forming the hydrogen release layer by depositing Cu as the third material on the porous substrate with an electroless plating method using a copper plating solution containing polyethylene glycol with a concentration in a range of 20 ppm to 40 ppm;
forming the lattice expansion layer by depositing the first material on the hydrogen release layer with an evaporation method; and
forming the hydrogen dissociation and transmission layer by depositing the second material on the lattice expansion layer with the evaporation method.

Assignees

• Toyota Motor Co Ltd

Inventors

• Takata Satoshi
• Kogure Tomonari

Classifications

• B01D71/022 Primary

  Metals · CPC title

• C01B2210/0042

  Making ultrapure specific gas · CPC title

• B01D2239/1291

  Other parameters · CPC title

• B01D2239/1208

  Porosity · CPC title

• B01D2239/0478

  on a layer of the filter · CPC title