Oxygen-induced multimodal ultramicroporous structure in 10-nm-thick carbon membranes for enhanced hydrogen separation

Carbon membranes yielding high selectivity as well as high permeance are attractive to advance the membrane-based gas separation. Herein, we report ultrathin carbon membranes (UCMs) which deliver enhanced gas separation performance through oxygen-modulated pyrolysis of poly(4-vinylpyridine) precursor. We show that O₂ in pyrolysis environment, transforms the otherwise uniform carbon network featuring a ~ 3.9 Å characteristic interlayer spacing into disrupted UCMs (d-UCMs). These d-UCMs possess a multimodal ultramicroporous structure characterized by distinct d-spacings of ~3.4 Å, 3.9 Å, and 5.5 Å. This optimized distribution of free volume in a 10-nm-thick membrane enables a record combination of H₂ permeance exceeding 10,000 gas permeation units (GPUs) and H₂/N₂ mixture selectivity surpassing 200. Meanwhile, d-UCM exhibits physical and thermal stability, showing no aging over 7 days of elevated temperature permeance testing, which overcomes the common issue of rapid aging in carbon membranes. Mechanistic investigations reveal that O₂ pyrolysis environment selectively removes relatively weakly-bound carbon species, altering pyrolysis intermediates, resulting in a nitrogen-rich framework with disordered nanodomains and heterogeneous ultramicroporosity. This work advances the material chemistry of ultrathin carbon membranes, attractive for ultrafast and high-precision molecular-sieving for molecular separation.