Composites including incompatible polymers and / or other incompatible materials

Abstract

Described herein are composites, methods of making composites, and methods of using composites. The composites include incompatible polymers and / or other incompatible materials. The composites are useful in a variety of industrial applications. The composites comprise a first component comprising a first material comprising a fluid-permeable portion and a second component comprising a second material incompatible with the first material; the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material and the interface forms a third component that separates at least a portion of the first component from the second component.

Description

COMPOSITES INCLUDING INCOMPATIBLE POLYMERS AND / OR OTHERINCOMPATIBLE MATERIALSFIELD OF DISCLOSURE

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 539,841 filed September 22, 2023, the disclosures of which are incorporated herein by reference in its entirety.

[0002] This disclosure is directed to composites, methods of making composites, and methods of using composites. The composites include incompatible polymers and / or other incompatible materials. The composites are useful in a variety of industrial applications.BACKGROUND

[0003] It is desirable to couple incompatible polymers and / or other incompatible materials to achieve composite materials where incompatible polymers and / or other incompatible materials are strongly bonded to each other at molecular level to improve strength, adhesion, durability, and sealing properties in a variety7of applications. Conventional techniques for such coupling include various welding technologies. However, conventional welding technologies are insufficient to weld certain combinations of incompatible polymers and / or other incompatible materials. For example, perfluorinated sulfonic acid (PFSA) polymer cannot be welded on common polymers such as polyethylene, polyether sulfone, and polypropylene. Instead, undesirable adhesives must be utilized to couple such incompatible polymer materials.

[0004] The insufficiencies of conventional welding technologies are particularly pronounced in applications requiring elevated temperatures and / or pressures. For example, sealing gaskets including polymer composites useful in energy conversion devices are exposed to high operating pressures and temperatures, which lead to deformation, degradation, and failure of the membranes, polymer composites and other components exposed to elevated conditions.

[0005] Accordingly, the present application seeks to provide composites including incompatible polymers and / or other incompatible materials. It was surprisingly discovered in the present application that composites including incompatible polymers and / or other incompatible materials could be produced by coupling the incompatible polymers and / or other incompatible materials with an interface including one material contained in a fluid-permeable portion of another material.

[0006] Described herein are composites, methods of making composites, and methods of using composites. The composites include incompatible polymers and / or other incompatible materials.BRIEF DESCRIPTION OF THE DISCLOSURE

[0007] In one aspect, provided herein is a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component.

[0008] In another aspect, provided herein is a method of making a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: (i) receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and (ii) solidifying the liquid component in the fluid-permeable portion of the first material.

[0009] In yet another aspect, provided herein is a method of using a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: (i) using the composite to couple a first surface comprising the first material and a second surface comprising the second material.

[0010] In yet another aspect, provided herein is a membrane electrode assembly (MEA) comprising: a membrane; at least one electrocatalyst layer disposed on a side of the membrane;at least one gas diffusion substrate in physical contact with the at least one electrocatalyst layer; and a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component; wherein the composite is coupled to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from surfaces of the membrane, surfaces of gaskets, surfaces of sealing gaskets, surfaces of the at least one electrocatalyst layer, surfaces of the at least one gas diffusion substrate, and combinations thereof.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Fig. 1A is a diagram depicting an exemplary embodiment of a composite in accordance with the present disclosure.

[0012] Fig. IB is a diagram depicting an exemplary embodiment of a composite in accordance with the present disclosure.

[0013] Fig. 2 is a diagram depicting an exemplary embodiment of a product in accordance with the present disclosure.

[0014] Fig. 3 is a diagram depicting an exemplary embodiment of a composite in accordance with the present disclosure.

[0015] Fig. 4 is a diagram depicting an exemplary embodiment of a cross-sectional view of an assembly in accordance with the present disclosure.

[0016] Fig. 5 is a diagram depicting an exemplary embodiment of a composite in accordance with the present disclosure.

[0017] Fig. 6 is a diagram depicting an exemplary' embodiment of a product in accordance with the present disclosure.

[0018] Fig. 7 is a method flow chart depicting an exemplary embodiment of a method in accordance with the present disclosure.

[0019] Fig. 8 is a method flow chart depicting an exemplary embodiment of a method in accordance with the present disclosure.

[0020] Fig. 9 is a diagram depicting an exemplary embodiment of an assembly in accordance with the present disclosure.

[0021] Fig. 10 is a diagram depicting an exemplary embodiment of a material including a fluid permeable portion in accordance with the present disclosure.DETAILED DESCRIPTION OF THE DISCLOSURE

[0022] The present disclosure is directed to composites, methods of making composites, and methods of using composites. The composites include incompatible polymers and / or other incompatible materials.

[0023] As used herein, incompatible polymers and / or other incompatible materials are polymers and / or other materials that are chemically incompatible (e.g., by virtue of distinct hydrophobicity or hydrophilicity), polymers and / or other materials that cannot be fused together by thermal techniques or welding techniques, polymers and / or other materials that are immiscible, and / or polymers and / or other materials that possess distinct melt flow characteristics.

[0024] As used herein, compatible polymers or materials are polymers and / or other materials that are chemically compatible (e.g., by virtue of similar hydrophobicity or hydrophilicity), polymers and / or other materials that can be fused together by thermal techniques or welding techniques, polymers and / or other materials that are miscible, and / or polymers and / or other materials that possess similar melt flow characteristics.

[0025] In many embodiments, a composite according to the present disclosure includes a first component including a first material including a fluid-permeable portion, and a second component including a second material incompatible with the first material, wherein the first component and the second component are coupled at an interface including the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component.

[0026] Fig. 1A is an exemplary diagram of a composite 110. In this exemplary embodiment, composite 110 depicts an exemplary composite and is not intended to limit the composition embodiments. In the exemplary embodiment, composite 110 includes a first component 112 including a first material including a fluid-permeable portion, a second component 114 including a second material incompatible with the first material, and an interface 116. Interface 116 includes the second material contained in the fluid-permeableportion of the first material. Although the exemplary embodiment depicts first component 112, second component 114, and interface 116 as having certain sizes and thicknesses, this depiction is non-limiting.

[0027] Fig. IB is an exemplary diagram of a composite 110. In this exemplary embodiment, composite 1 10 depicts an exemplary composite and is not intended to limit the composition embodiments. In the exemplary embodiment, composite 110 includes a first layer of a first component 112 including a first material including a fluid-permeable portion, a second layer of the first component 113 including a third material, that is the same as, similar to, or different from the first material, optionally including a fluid-permeable portion, a second component 114 including a second material incompatible with the first material, and an interface 116. In this exemplary' embodiment, the second material of the second component 114 penetrates through the interface 116 and the first layer of the first component 112 and optionally partly through the second layer of the first component 113. That is. interface 116, the first component 1 12 and optionally the first component 1 13 each include the second material contained in their fluid-permeable portions. Although the exemplary- embodiment depicts first component 112, first component 113, second component 114. and interface 116 as having certain sizes and thicknesses, this depiction is non-limiting.

[0028] Generally, the first material may be any suitable material known in the art that facilitates the composites described herein. In some embodiments, the first material is selected from the group consisting of porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC). poly sulfone, poly ethersulfone, polyphenylsulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treated version thereof, mixtures thereof, and combinations thereof.

[0029] Generally, the first material may be treated to be hydrophilic according to any suitable method known in the art that facilitates the composites described herein. In some embodiments, hydrophilic treated versions thereof are treated to be hydrophilic by coating them with surfactants or other polymers and / or chemically functionalizing them with plasma and / or UV treatment.

[0030] Generally, the fluid-permeable portion may be any suitable fluid-permeable portion known in the art that facilitates the composites described herein. In some embodiments, the fluid-permeable portion is selected from the group consisting of pores,grooves, ridges, divots, indentations, holes, through-holes, and combinations thereof. The fluid-permeable portion is configured to receive a liquid component including the second material and a liquid carrier. The liquid component is subsequently solidified to provide mechanical interlocking of the first material and the second material.

[0031] Generally, the fluid-permeable portion of the first material may contain the second material in any suitable amount known in the art that facilitates the composites described herein. Portions of the fluid-permeable portion of the first material that contain the second material (e.g., in the interface) may be partially filled or completely filled, such that they are porous or non-porous, respectively.

[0032] In some embodiments, the second material is contained in about 1% to about 100%, about 10% to about 90%, about 20% to about 80%, about 30% to about 70%, about 40% to about 60%, or about 50% to about 60% of the fluid-permeable portion of the first material in the interface. In these embodiments, the percentages of the interface that contain the second material contained in the fluid-permeable portion of the first material include a total amount of the interface and are not limited to an individual or particular portion of the interface.

[0033] Generally, the liquid component may be any suitable liquid component known in the art that facilitates the composites described herein. In some embodiments, the liquid component includes the second material and a liquid carrier. In some embodiments, the liquid component does not include a molten polymer. In some embodiments, the liquid component is selected from the group consisting of dispersions, emulsions, solutions, and combinations thereof.

[0034] Generally, the liquid carrier may be any suitable liquid carrier known in the art that facilitates the composites described herein. Suitable liquid carriers include solvents that do not dissolve the first component and / or deform the fluid-permeable portion. In some embodiments, the liquid carrier is selected from the group consisting of water, aliphatic alcohols (e.g., methanol, ethanol, propanol, isopropanol, butanol, etc.), non-aliphatic alcohols, and combinations thereof.

[0035] In some embodiments, the fluid-permeable portion is symmetric, homogenous, and / or uniform. In some embodiments, the fluid-permeable portion possesses a symmetric, homogenous, and / or uniform distribution of pores, grooves, ridges, divots, indentations, holes, through-holes, or combinations thereof.

[0036] In some embodiments, the fluid-permeable portion is asymmetric, inhomogeneous, and / or non-uniform. In some embodiments, the fluid-permeable portion possesses an asymmetric, inhomogeneous, and / or non-uniform distribution of pores, grooves, ridges, divots, indentations, holes, through-holes, or combinations thereof. In some embodiments, the fluid-permeable portion possesses a first portion of pores, grooves, ridges, divots, indentations, holes, through-holes, or combinations thereof that is different from a second portion of pores, grooves, ridges, divots, indentations, holes, through-holes, and combinations thereof.

[0037] Fig. 10 is an exemplary diagram of a first component 1010. In this exemplary embodiment, first component 1010 depicts an exemplary first component and is not intended to limit the composition embodiments. In the exemplary' embodiment, first component 1010 includes a first material including a fluid-permeable portion 1012 and a non-fluid-permeable portion 1014. Fluid-permeable portion 1012 is asymmetric in that the left-hand side of the figure includes larger and deeper areas into which fluid can permeate, while the right-hand side of the figure includes smaller and shallower areas into which fluid can permeate.

[0038] In some embodiments, the fluid-permeable portion includes a porous portion. The porous portion may include a polymer having no chemically reactive functional groups on the polymer structure. In some embodiments, the porous portion may include a polyolefin such as polyethylene (PE), including but not limited to. ultrahigh molecular weight polyethylene (UHMWPE), low density polyethylene (LDPE) and high-density polyethylene (HDPE), or polypropylene (PP). In some embodiments, the porous portion may include a fluoropolymer such as polytetrafluoroethylene (PTFE) or expanded polytetrafluoroethylene (ePTFE) or polyvinylidene fluoride (PVDF), polyvinyl chloride (PVC). polystyrene, polysulfone, polyethersulfone, polyphenylsulfone, or polyarylethersulfone, polyphenylenesulfide, such as a Zirfon® separator membrane, or a combination thereof, that are suitable for use in water electrolysis applications.

[0039] The porous portion may be hydrophobic or hydrophilic as measured, for example, by the contact angle method. Hydrophilicity of a porous portion polymer may be increased by the addition of an additive or inorganic material, such as metal oxides, thereby forming a polymer composite. Metal oxides may be selected from the group of zirconium oxide, titanium oxide, bismuth oxide, cerium oxide, magnesium oxide, and combinations thereof. Other hydrophilic particles that may be used include nitrides and carbides of the Group IV elements of the periodic table. The hydrophilic particles may have a particle size of 0.5 to 2pm, of 0.15 to 1.00 un, or of 0.15 to 0.75 pm. A composite of a polymer, such as polyethylene and / or polysulfone, and an inorganic material such as silica, titanium dioxide and / or zirconium oxide, integrated into the polymer matrix, may be used to improve hydrophilicity of the porous portion.

[0040] In some embodiments, the porous portion includes an average pore size in a range of from about 0.1 pm to about 4 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0. 1 pm to about 2 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0. 1 pm to about 1 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0.5 pm to about 4 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0.5 pm to about 3 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0.5 pm to about 2 pm. In some embodiments, the porous portion includes an average pore size in a range of from about 0.5 pm to about 1 pm. The average pore size may be measured, for example, by a capillary flow porometer.

[0041] In some embodiments, the porous portion includes a percent porosity in a range of from about 1% to about 99%. In some embodiments, the porous portion includes a percent porosity in a range of from about 10% to about 90%. In some embodiments, the porous portion includes a percent porosity in a range of from about 20% to about 80%. In some embodiments, the porous portion includes a percent porosity in a range of from about 30% to about 70%. In some embodiments, the porous portion includes a percent porosity in a range of from about 40% to about 60%. In some embodiments, the porous portion includes a percent porosity in a range of from about 40% to about 80%. In some embodiments, the porous portion includes a percent porosity in a range of from about 50% to about 80%. In some embodiments, the porous portion includes a percent porosity in a range of from about 60% to about 80%. In some embodiments, the porous portion includes a percent porosity in a range of from about 50% to about 70%.

[0042] By way of example and not limitation, the first material may be cast, extruded, phase inversion, woven, or non-woven, including but not limited to a woven or non-woven fabric, spun woven mat, mesh, web, or cast or extruded layer or film. The first material may include one or more than one layer, or other structure or form, or combinations thereof.

[0043] In some embodiments, the first material does not include a woven fabric. In some embodiments, the first material does not include a fabric. In some embodiments, the first material is non-woven and / or solid.

[0044] Generally, the porous portion may include any suitable thickness known in the art that facilitates the composites described herein. In some embodiments, the porous portion has a thickness in a range of from about 1 pm to about 300 pm. In some embodiments, the porous portion has a thickness in a range of from about 50 pm to about 250 pm. In some embodiments, the porous portion has a thickness in a range of from about 75 pm to about 225 pm. In some embodiments, the porous portion has a thickness in a range of from about 100 pm to about 150 pm.

[0045] Generally, the second material may be any suitable material known in the art that facilitates the composites described herein. In some embodiments, the second material is a polymer that can be carried in a solvent system. In some embodiments, the second material is selected from the group consisting of hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fully fluorinated polymer electrolytes, ionomers, cationic exchange polymers, anionic exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene-based fluoropolymer-copolymers, fluorinated sulfonic acids or their sulfonate salts, such as perfluorosulfonic acid (PFSA) polymers (e.g., NafionTM polymers) or their sulfonate salts, copolymers thereof, and combinations thereof.

[0046] Fluorinated sulfonic acids and fluorinated sulfonate salts can be made by hydrolyzing and then optionally protonating fluorinated sulfonyl fluoride polymers. Suitable fluorinated sulfonyl fluoride polymers include at least one fluorinated sulfonyl fluoride repeat unit and optionally one or more repeat units, resulting from the free radical polymerization of at least one fluorinated sulfonyl fluoride monomer and optionally one or more monomers. In some embodiments, the sulfonyl fluoride polymer is a copolymer made from two or more monomers. In addition to the sulfonyl fluoride monomer, suitable comonomers include, but are not limited to, tetrafluoroethylene (TFE), hexafluoropropylene, vinyl fluoride, vinylidene fluoride, trifluoroethylene, chlorotrifluoroethy lene, perfluoro (alkyl vinyl ether), and mixtures thereof. For example, it may be a copolymer of a sulfonyl fluoride-containing monomer with TFE, resulting in a repeat unit -[CF2-CF2]-, or with other comonomers. Monomers having pendant phosphonic acid groups may also be incorporated into the fluorinated sulfonyl fluoride polymer to yield, after conversion, a fluorinated ionomer containing both sulfonic acid and / or sulfonate groups and phosphonic acid and / or phosphonate groups.

[0047] A class of preferred fluorinated sulfonyl fluoride polymers include a highly fluorinated, most preferably perfluorinated, carbon backbone with a side chain represented by the formula -(O-CF2CFRt)a-O-CF2CFRfSO2F, where R1and Rfare independently selected from F, Cl, or a perfluorinated alkyd group having 1 to 10 carbon atoms and a = 0, 1 or 2. These polymers are converted to sulfonates or sulfonic acids, for example, polymers disclosed in U.S. Patent No. 3.282,875, in U.S. Patent No. 4,358,545. or in U.S. Patent No. 4,940,525.

[0048] One preferred fluorinated sulfonyl fluoride polymer includes a perfluorocarbon backbone and a side chain represented by the formula -O-CF2CF(CF3)-O-CF2CF2SO2F. Fluorinated ionomers containing sulfonate or sulfonic acid groups of this type are disclosed in U.S. PatentNo. 3,282,875 and may be made by copolymerization of tetrafluoroethylene (TFE) and the perfluorinated vinyl ether CF2=CF-O-CF2CF(CF3)-O-CF2CF2SC>2F, perfluoro(3,6 dioxa-4 methyl 7 octenesulfonyl fluoride) (PSEPVE, also called long side-chain or LSC), followed by conversion to sulfonate groups by hydrolysis of the sulfonyl fluoride groups and conversion to the proton or salt form if desired for the particular application. Another preferred fluorinated sulfonyl fluoride polymer is of the type disclosed in U.S. Patent No. 4,358,545 and U.S. Patent No. 4,940.525, which has the side chain -O-CF2CF2SO2F. This polymer may be made by copolymerization of TFE and the perfluorinated vinyl ether CF2=CF-O-CF2CF2SO2F, perfluoro(3 oxa-4-pentenesulfonyl fluoride) (PFSVE, also called short side-chain or SSC), followed by hydrolysis and conversion to the proton or salt form if desired for the particular application.

[0049] After hydrolysis and optional conversion to the proton form, a fluorinated sulfonate or sulfonic acid polymer is formed. As used herein, sulfonate or sulfonic acid groups refers to either sulfonic acid groups or salts of sulfonic acid, preferably alkali metal or ammonium salts. Preferred functional groups are represented by the formula -SO3X wherein X is H, Li, Na, K or N(R1)(R2)(R3)(R4), where R1, R2, R3, and R4are the same or different and are H, CH3, or C2H5. In exemplary embodiments, the fluorinated sulfonate or sulfonic acid polymer is of the type available under the trade name of Nafion™ (The Chemours Company FC, LLC, Wilmington, DE).

[0050] For example, the fluorinated sulfonate or sulfonic acid may contain the repeat unit:

[0051] -[CF2-CF((CF2)b-(O-(CFRf)e)a-O-(CFR'f)dSO3X)]- wherein b is 0 or 1 ; c is an integer from 1 to 16; a is 0, 1, or 2; d is an integer from 1 to 16; Rf and R'f are independently selected from F, Cl or a perfluorinated alkyl grouphaving 1 to 10 carbon atoms; and X is H. Li, Na, K or N(R1)(R2)(R3)(R4) w here R1, R2, R3, and R4are the same or different and are H, CH? or C2H5. For clarity, it is noted that the segment ((CF2)b-(O-(CF2CFRf)c)a-O-(CF2CFR'f)dSO3X) in the structure above is the pendant chain from the perfluorinated polymer backbone. Branched pendant chains having multiple sulfonic acid groups are also encompassed.

[0052] Specific ion exchange polymer backbones may include one or more units represented by the following formulae:-[CF2-CF[-O-CF2CF(CF3)-O-(CF2)m-SO3M)]- wherein m is 1-6, and M is an alkali metal;-[CF2-CF(-O-(CF2)m-SO3M)]- wherein m is 1 -6, and M is an alkali metal;wherein Q1is a perfluoroalkylene group optionally having an etheric oxygen atom, Q2is a single bond or a perfluoroalkylene group optionally having an etheric oxygen atom, R / 3is a perfluoroalkyl group optionally having an etheric oxygen atom, X1is an oxygen atom, a nitrogen atom or a carbon atom, when X1is an oxygen atom, a is 0, when X1is a nitrogen atom, a is 1, and when X1is a carbon atom, a is 2, Y is a fluorine atom or a monovalent perfluoro organic group, r is 0 or 1, and M is an alkali metal;wherein R / '1 1is a single bond or a Ci-6 linear perfluoroalkylene group which may have an etheric oxygen atom, and RF12is a Ci-6 linear perfluoroalkylene group, r is 0 or 1, and M is an alkali metal.

[0053] In some embodiments, the fluorinated sulfonate or sulfonic acid has an ion exchange ratio of less than about 13.2. As used herein, ion exchange ratio (IXR) refers to the number of carbon atoms in the polymer backbone in relation to the number of sulfonyl fluoride, sulfonate or sulfonic acid groups. In some embodiments, the IXR of a fluorinated sulfonyl fluoride polymer can be related to the equivalent weight (EW) of the correspondingfluorinated sulfonate or sulfonic acid polymer by the equation EW = (50 x IXR) + MWSC-19, where MWSCis the molecular weight of the side chain of the fluorinated sulfonate or sulfonic acid polymer. In one aspect, the fluorinated sulfonate or sulfonic acid polymer has an IXR less than about 13.2; in another aspect, less than about 12.7; in another aspect, less than about 12.1; and in another aspect, less than about 11.7; or any value, range, or sub-range therebetween. In one aspect, the fluorinated sulfonate or sulfonic acid polymer has an IXR of at least 7. 1 ; in another aspect, at least 8. 1 ; in another aspect, at least 9. 1 ; and in another aspect, at least 10. 1; or any value, range, or sub-range therebetween.

[0054] In some embodiments, the fluorinated sulfonate or sulfonic acid has an equivalent weight (EW) less than about 1100; alternatively less than about 1000; alternatively less than about 980; alternatively less than about 950; alternatively less than about 930, or any value, range, or sub-range therebetween. In one aspect, the fluorinated ionomer has an EW of at least about 530; alternatively, at least about 580; alternatively, at least about 630; alternatively at least about 680, or any value, range, or sub-range therebetween. As used herein, (EW) refers to the weight of the corresponding fluorinated sulfonic acid polymer in proton form required to neutralize one equivalent of NaOH.

[0055] In some embodiments, the ion exchange polymer backbone comprises polyphenylene, polyphenylene oxide, polysulfone, polyethylene, polyether ether ketone, and / or poly(aryl ether sulfone).

[0056] In some embodiments, the second material comprises an ion exchange polymer. The ion exchange polymer may include one or more functional groups to improve ionic conductivity, water uptake, chemical stability, and / or mechanical properties. In some embodiments, the ion exchange polymer is a cationic exchange polymer comprising a functional group selected from the group consisting of sulfonate, phosphate, derivatives thereof, and combinations thereof. In some embodiments, the ion exchange polymer is an anionic exchange polymer comprising a functional group selected from the group consisting of ammonium, piperidinium, imidazolium, guanidinium, benzimidazolium, pyrrolidium, spirocyclic ammonium, phosphonium, derivatives thereof, and combinations thereof. In one embodiment, an AEM separator includes a selective material that includes poly(aryl piperidinium).

[0057] Anion exchange capacity of a cationic or anionic exchange polymer, or poly electrolyte, suitable for use herein is in a range of from about 0.8 meq / g to about 2.5 meq / g dry polymer. The particle size of a filler in the polyelectrolyte may be less than or equal to 10pm, or less than or equal to 4 pm, or less than or equal to 3 pm, or less than or equal to 2 qm, or less than or equal to 1 pm, such as from 0. 1 pm to 4 pm, or from 0.2 pm to 3 pm, or from 0.5 pun to 1 pirn. In some embodiments, the average particle surface area is approximately 4 m2 / g.

[0058] Generally, the composite may be in any suitable form of composite known in the art that facilitates the composites described herein. In some embodiments, the composite is in a form selected from the group consisting of films, tapes, welding tapes, welding mediators, sheets, blocks, bars, rods, tubes, and combinations thereof.

[0059] In some embodiments, a portion of the composite is symmetrical. In some embodiments, a component of the composite is symmetrical. In some embodiments, the entire composite is symmetrical.

[0060] In some embodiments, a portion of the composite is asymmetrical. In some embodiments, a component of the composite is asymmetrical. In some embodiments, the entire composite is asymmetrical.

[0061] In some embodiments, the composite is in a shape selected from the group consisting of symmetrical shapes, asymmetrical shapes, regular shapes, irregular shapes, and combinations thereof. In some embodiments, the composite is in a shape selected from the group consisting of regular polygons, irregular polygons, circles, tn angles, squares, rectangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, hendecagons, dodecagons, partial shapes thereof, and combinations thereof.

[0062] In some embodiments, a component of the composite is in a shape selected from the group consisting of symmetrical shapes, asymmetrical shapes, regular shapes, irregular shapes, and combinations thereof. In some embodiments, the composite is in ashape selected from the group consisting of regular polygons, irregular polygons, circles, triangles, squares, rectangles, pentagons, hexagons, heptagons, octagons, nonagons, decagons, hendecagons, dodecagons, partial shapes thereof, and combinations thereof.

[0063] Generally, the composite may include any suitable number of components know n in the art that facilitates the composites described herein. In some embodiments, the composite includes a distinct interface component. In some embodiments, the composite further includes an interface within one or more components.

[0064] In some embodiments, the composite is a three-component composite. In these embodiments, the interface is present as a distinct third component that separates the firstcomponent and the second component. The third component is in contact with both the first component and the second component. The third component may be coupled to the first component and the second component by any suitable coupling technique known in the art that facilitates the composites described herein. The third component may be part of a monolithic or multilayered first component and represents the portion of the first component that is filled with the second material.

[0065] Generally, each component may include any suitable number layers known in the art that facilitates the composites described herein. In some embodiments, the first component includes one layer, two layers, three layers, four layers, or more than four layers. In some embodiments, the second component includes one layer, two layers, three layers, four layers, or more than four layers. In some embodiments, the third component includes one layer, two layers, three layers, four layers, or more than four layers. Each layer of a component may include the same or different material(s) or any combination thereof.

[0066] In some embodiments, the first component and the second component are coupled at the interface by mechanical interlocking. In some embodiments, the first component and the second component are coupled at the interface by entanglement of the first material and the second material. In some embodiments, the first component and the second component are free of chemical bonding. In some embodiments, the first component and the second component are free of thermal fusion.

[0067] Generally, each component of the composite may possess any suitable thickness known in the art that facilitates the composites described herein.

[0068] Generally, each component of the composite may possess any suitable hydrophobicity or hydrophilicity known in the art that facilitates the composites described herein.

[0069] Generally, each component of the composite may possess any suitable uniformity know n in the art that facilitates the composites described herein.

[0070] Generally, the fluid-permeable portion may possess any suitable tortuosity know n in the art that facilitates the composites described herein.

[0071] In some embodiments, the composite is a welding tape including at least two different materials on outer surfaces, with the materials mechanically entangled inside an inner portion of the tape. This entangled domain provides mechanical strength and adhesion that cannot be achieved by conventional welding processes. The wielding tape may be used tocouple two base plates that are incompatible, i.e., they cannot be welded together without a welding tape. During the welding process of two base plates, the welding tape is placed between two base plates where each surface of the welding tape is aligned against similar welding surfaces of the two base plates, thereby ensuring a strong bond between the two surfaces. Consequently, the welding tape may provide good adhesion without an adhesive or excessive compression between two base plates.

[0072] Generally, the composites may be made according to any suitable method known in the art that facilitates the composites described herein. In some embodiments, a composite according to the present disclosure is made by a method including: (i) receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and (ii) solidifying the liquid component in the fluid-permeable portion of the first material.

[0073] In some embodiments, the method comprises solidifying all of the liquid component within the fluid-permeable portion of the first material. In some embodiments, the method comprises solidifying a portion of the liquid component outside the fluid-permeable portion of the first material. In these embodiments, the portion of the liquid component solidified outside the fluid-permeable portion of the first material may be solidified on an outer surface of the first material.

[0074] Fig. 7 is an exemplary' method flow chart 710. In this exemplary' embodiment, method flow chart 710 depicts exemplary steps of the method embodiments of making a composite described herein and is not intended to limit the method embodiments. In the exemplary embodiment, the method includes receiving 712 a liquid component including the second material and a liquid carrier in a fluid-permeable portion of a first material, and solidifying 714 the liquid component in the fluid-permeable portion of the first material.

[0075] Generally, the liquid component including the second material and a liquid carrier may be received in the fluid-permeable portion of the first material according to any suitable method known in the art that facilitates the composites described herein. In some embodiments, the liquid component including the second material and a liquid carrier is received in the fluid-permeable portion of the first material upon application of the liquid component with a technique selected from the group consisting of coating, slot die coating, doctor blade coating, rod coating, Mayer rod coating, gravure coating, electrocoating, dipping, spraying, and combinations thereof.

[0076] In some embodiments, the liquid component including the second material and a liquid carrier is received in the fluid-permeable portion of the first material at a temperature less than about 50 °C. In some embodiments, the liquid component including the second material and a liquid carrier is received in the fluid-permeable portion of the first material under ambient conditions.

[0077] Generally, the liquid component may be solidified according to any suitable method known in the art that facilitates the composites described herein. In these embodiments, solidifying the liquid component results in removal of the liquid carrier and at least a portion of the second material being contained in the fluid-permeable portion of the first material. In some embodiments, solidifying the liquid component results in removal of the liquid carrier and all of the second material being contained in the fluid-permeable portion of the first material. In some embodiments, solidifying the liquid component results in removal of the liquid carrier and at least a portion of the second material being on an outer surface of the first material.

[0078] In some embodiments, solidifying the liquid component in the fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component. Generally, the liquid carrier of the liquid component may be dried accordingly to any suitable drying method known in the art that facilitates the composites described herein. In some embodiments, solidifying the liquid component in the fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a combination of temperature(s) and time(s) that improves adhesion during a welding process. In some embodiments, solidifying the liquid component in the fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at an elevated temperature. In some embodiments, solidifying the liquid component in the fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature less than about 150 °C. In some embodiments, solidifying the liquid component in the fluid- permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature greater than about 50 °C. In some embodiments, solidifying the liquid component in the fluid-permeable portion of the first material includes drying the liquid carrier of the liquid component at a temperature less than the melting point of the first material.

[0079] Generally, each element of the method may be tuned according to any suitable method known in the art in order to facilitate the composites described herein. Such elementsincluding coating techniques, line speeds, temperatures, component thicknesses, dispersion properties, solvents, and combinations thereof.

[0080] Suitable solvents include solvents that do not dissolve the first component and / or deform the fluid-permeable portion. In some embodiments, the solvent is selected from the group consisting of water, aliphatic alcohols (e g., methanol, ethanol, propanol, isopropanol, butanol, etc.), non-aliphatic alcohols, and combinations thereof.

[0081] Generally, the composites may be used according to any suitable method known in the art that facilitates the composites described herein. In some embodiments, a composite according to the present disclosure is used according to a method including: (i) using the composite to couple a first surface including a material compatible with the first material and a second surface including a material compatible with the second material

[0082] Fig. 8 is an exemplary method flow chart 810. In this exemplary embodiment, method flow chart 810 depicts exemplary steps of the method embodiments of using a composite described herein and is not intended to limit the method embodiments. In the exemplary embodiment, the method includes using 812 a composite to couple a first surface including a material compatible with a first material and a second surface including a material compatible with a second material.

[0083] Generally, the first surface and / or the second surface may each be any suitable surface known in the art that facilitates the composites described herein. In some embodiments, the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of membranes, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

[0084] Generally, the first surface and / or the second surface may each include any suitable material known in the art that facilitates the composites described herein. In some embodiments, the first surface and / or the second surface each include a material compatible with the first material and / or the second material. In some embodiments, the first surface and / or the second surface each include a material identical to the first material and / or thesecond material. In some embodiments, the first surface and / or the second surface each include a material different than the first material and / or the second material.

[0085] In some embodiments, the first surface and the second surface are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0086] In some embodiments, the method further includes coupling each of the first surface and the second surface to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0087] In some embodiments, the composite may be extended on a gas diffusion substrate, porous transport layer, and / or a catalyst layer. Additional entanglement of the composite with the gas diffusion material or the porous transport layer may further increase the bonding strength.

[0088] A membrane electrode assembly (MEA) is commonly used in energy conversion systems, including fuel cells and water electrolyzers. A MEA includes a membrane at the center, catalyst layers adjacent to both sides of the membrane and gas diffusion substrates or porous transport layers on the outer surface of the assembly.

[0089] The MEA can be made by several methods. For example, an electrocatalyst can be applied to a gas diffusion substrate to form gas diffusion electrodes. Two gas diffusion electrodes can be pressed on a membrane to form an MEA. Alternatively, electrocatalyst layers can be first coated on both sides of a membrane to form a catalyst coated membrane (CCM). Then, gas diffusion substrates can be applied on a CCM, adjacent to the electrocatalyst layers. In some applications, porous transport layers can be used instead of gas diffusion substrates.

[0090] In some embodiments, described herein is a membrane electrode assembly (MEA) including the composite. In some embodiments, described herein is an assembly including the MEA.

[0091] Fig. 9 is an exemplary diagram of an assembly 910. In this exemplary' embodiment, assembly 910 depicts an exemplary’ assembly and is not intended to limit the composition embodiments. In the exemplary embodiment, assembly 610 includes a first sealing gasket 912, a first composite 914, an electrocatalyst 916 disposed on a membrane 918, a second composite 920, and a second sealing gasket 920. The electrocatalyst 916 disposed on a membrane 918 is part of a membrane electrode assembly that may also include one or more gas diffusion substrates, porous transport layer, and a second electrocatalyst (not shown). The composites enable coupling of the membrane electrode assembly to two nonporous gaskets.

[0092] In some embodiments, described herein is a membrane electrode assembly (MEA) including: a membrane; at least one electrocatalyst layer disposed on a side of the membrane; optionally at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and a composite including: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component; wherein the composite is coupled to a first surface comprising a material compatible w ith the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from surfaces of sealing gaskets, surfaces of the membrane, surfaces of the at least one electrocatalyst layer, surfaces of the at least one gas diffusion substrate, and combinations thereof.

[0093] In some embodiments, the first surface and / or the second surface are each coupled to the composite with a w elding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact wielding, extrusion welding, hot plate welding, and combinations thereof.

[0094] In some embodiments, only the first surface is coupled to the composite. In some embodiments, only the second surface is coupled to the composite. In some embodiments, both the first surface and the second surface are coupled to the composite.

[0095] Generally, the at least one electrocatalyst layer may include any suitable number of electrocatalyst layers known in the art that facilitates the composites described herein. In some embodiments, the at least one electrocatalyst layer comprises two electrocatalyst layers, wherein the two electrocatalyst layers are disposed on different sides of the membrane. In some embodiments, the at least one electrocatalyst layer comprises two electrocatalyst layers, wherein the two electrocatalyst layers are disposed on opposite sides of the membrane.

[0096] Generally, the at least one gas diffusion substrate may include any suitable number of gas diffusion substrates or porous transport layers known in the art that facilitates the composites described herein. In some embodiments, the at least one gas diffusion substrate includes two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

[0097] In some embodiments, the at least one gas diffusion substrate and / or porous transport layer is aligned with the at least one electrocatalyst layer. In these embodiments, the at least one gas diffusion substrate may be smaller than the at least one electrocatalyst layer such that a portion of the at least one electrocatalyst layer is not covered by the at least one gas diffusion substrate. In the alternative, the at least one gas diffusion substrate may be larger than the at least one electrocatalyst layer such that the at least one electrocatalyst layer is totally covered by the at least one gas diffusion substrate.

[0098] In some embodiments, the composite is in contact with an edge of each of the two electrocatalyst layers. In these embodiments, the composite forms an edge layer of the MEA.

[0099] In some embodiments, the composite is in contact with an edge of at least one gas diffusion substrate and / or porous transport layer.

[0100] In some embodiments, described herein is an assembly including: at least one sealing gasket comprising a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and the MEA; wherein the composite is coupled to the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket.

[0101] In some embodiments, the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infraredwelding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0102] In some embodiments, the assembly includes at least two sealing gaskets, wherein each of the at least two sealing gaskets are coupled to the composite.

[0103] In some embodiments, the assembly is a sealed assembly. In these embodiments, a sealed is formed by couplings between the at least two sealing gaskets and the composite.

[0104] Generally, the membrane may include any suitable material known in the art that facilitates the composites described herein. In some embodiments, the membrane includes a polymer that is the same as or similar to the second material of the composite. In some embodiments, the membrane includes a polymer selected from the group consisting of hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fully fluorinated polymer electrolytes, ionomers, cationic exchange polymers, anionic exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene-based fluoropolymercopolymers, fluorinated sulfonic acids or their sulfonate salts, such as perfluoro sulfonic acid (PFSA) polymers (e.g., NafionTM polymers) or their sulfonate salts, copolymers thereof, and combinations thereof. In some embodiments, the membrane includes a perfluorinated sulfonate ionomer or an anion exchange membrane.

[0105] In some embodiments, the membrane, diaphragm, or separator includes a reinforcement material. The reinforcement material may include any suitable reinforcement material known in the art, including PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or combinations thereof in any form, including mesh, film, w oven, non-woven, and expanded.

[0106] In some embodiments, the membrane includes multiple material layers and additives, such as gas recombination catalysts, radical scavenging species, and combinations thereof.

[0107] Generally, the electrocatalyst layer may include any suitable material known in the art that facilitates the composites described herein. In some embodiments, the electrocatalyst layer includes at least one electrocatalyst and at least one ion conducting polymer as a binder. The electrocatalysts may include fine metal powders and / or may be supported on an electrically conducting carbon-based powder. The electrocatalyst metal may be selected from the group consisting of platinum group metals, including platinum, palladium, iridium, ruthenium, rhodium, or osmium, oxides thereof, alloys thereof, and combinations thereof.

[0108] Generally, the at least one gas diffusion substrate may include any suitable gas diffusion substrate known in the art that facilitates the composites described herein. In some embodiments, the at least one gas diffusion substrate includes carbon paper, woven carbon cloths, non-woven carbon fiber webs, or combinations thereof.

[0109] Generally, the at least one porous transport layer may include any suitable porous transport layer known in the art that facilitates the composites described herein. In some embodiments, the at least one porous transport layer includes a structure selected from the group consisting of felt, sintered powder sheets, foams, woven mesh, fine mesh, hole- patterned thin plates, and combinations thereof. The at least one porous transport layer may be made of metals, metal oxides, and / or alloys, including stainless steel, nickel, titanium, titanium oxide, and combinations thereof. The at least one porous transport layer may include a coating layer of TiOx, TaOx, NbOx, NiCoOx, Ta. Nb, Zr, Ni. Ti Nx, TaNx, ZrNx. TaCx, CrCx, T1B2. TaBx, other materials, or mixtures of thereof.

[0110] In many embodiments, a product includes the composite according to the present disclosure. In some embodiments, the composite couples a first surface including the first material and a second surface including the second material. In some embodiments, the product includes the MEA. In some embodiments, the product includes the assembly.

[0111] Fig. 2 is an exemplary' diagram of a product 210. In this exemplary embodiment, product 210 depicts an exemplary product and is not intended to limit the composition embodiments. In the exemplary’ embodiment, product 210 includes a first surface 212 including a first material and a second surface 214 including a second material. The first surface 212 is coupled to the second surface 214 by’ the composite 110. The first surface 212 is of the same material or a similar material as the first component 112 and the second surface 214 is of the same material or a similar material as the second component 114.

[0112] Fig. 3 is an exemplary diagram of a composite 310 including two composites 110 that are coupled together by a common material. In this exemplary embodiment, composite 310 depicts an exemplary' composite and is not intended to limit the composition embodiments. In the exemplary’ embodiment, composite 310 includes a first component 314 including a first material including a fluid-permeable portion, a second component 312 including a second material incompatible with the first material, and an interface 316. Interface 316 includes the second material contained in the fluid-permeable portion of the first material. Composite 310 also includes a third component 320 including a third material incompatible with the first material, and an interface 318. Interface 318 includes the secondmaterial contained in the fluid-permeable portion of the third material. Interface 316 and interface 318 may be the same or different. First component 314 and third component 320 may be the same or different. Although the exemplary embodiment depicts second component 312 as the common material, this depiction is non-limiting. It is alternatively possible to include first component 314 or third component 320 as the common material. Although the exemplary embodiment depicts first component 314. second component 312, interface 316, interface 318, and third component 320 as having certain sizes and thicknesses, this depiction is non-limiting.

[0113] Fig. 4 is an exemplary diagram of a product 410. In this exemplary embodiment, product 410 depicts an exemplary product and is not intended to limit the composition embodiments. This exemplary diagram is a cross-sectional image of the assembly of Fig. 9 once the components depicted in Fig. 9 are welded together. The composites 310 in Fig. 4 correspond to the first composite 914 and the second composite 920 and the membrane 416 corresponds to the membrane 918. That is, the top halves of the composites 310 belong to a first composite and the bottom halves of the composites 310 belong to a second composite such that the membrane 416 is sandwiched between the two composites. More particularly, in the exemplary embodiment, product 410 includes a first electrocatalyst layer 412 and a second electrocatalyst layer 414 disposed on a membrane 416. Membrane 416 includes a material that is not compatible with the material of first component 314. The first electrocatalyst 412 and the second electrocatalyst 414 disposed on the membrane 416 is part of a membrane electrode assembly that may also include one or more gas diffusion substrates or porous transport layers (not shown). The composites enable coupling of the membrane electrode assembly to two sealing gaskets. Membrane 416 is bonded on periphery edges to the composites 310.

[0114] Fig. 5 is an exemplary diagram of a composite 510. In this exemplary embodiment, composite 510 depicts an exemplary composite and is not intended to limit the composition embodiments. In the exemplary embodiment, composite 510 includes a first component 512 including a first material including a fluid-permeable portion, a second component 514 including a second material incompatible with the first material, and an interface 516. Interface 516 includes the second material contained in the fluid-permeable portion of the first material. In the exemplary embodiment, composite 510 is configured so that it may be wrapped around a component for coupling. Although the exemplaryembodiment depicts first component 512, second component 514, and interface 516 as having certain sizes and thicknesses, this depiction is non-limiting.

[0115] Fig. 6 is an exemplary diagram of a product 610. In this exemplary' embodiment, product 610 depicts an exemplary product and is not intended to limit the composition embodiments. In the exemplary embodiment, product 610 includes a first electrocatalyst 612 and a second electrocatalyst 614. The first electrocatalyst 612 and the second electrocatalyst 614 are separated by a membrane 616. Membrane 616 includes a material that is compatible with the material of first component 512. Membrane 616 is bonded on periphery edges to at least one composite 510. The at least one composite 510 may be only one composite 510 or include more than one composite 510. Where the at least one composite 510 is only one composite 510, the depicted composites 510 are a single composite that encompasses the membrane 616 and contacts the membrane 616 on periphery’ edges. Where the at least one composite 510 includes more than one composite 510, the depicted composites 510 are different composites that each contact the membrane 61 on periphery edges.

[0116] In some embodiments, the product is configured to be used for long durations. In some embodiments, the product is configured to be used at an elevated pressure and / or a temperature. In some embodiments, the product is configured to be used at a differential pressure and / or a differential temperature. In some embodiments, the product is configured to be used for long durations at an elevated pressure and / or a temperature. In some embodiments, the product is configured to be used for long durations at a differential pressure and / or a differential temperature. In some embodiments, the long duration is in a range of from about 1 year to about 20 years. In some embodiments, the long duration is in a range of from about 5 years to about 20 years. In some embodiments, the long duration is in a range of from about 10 years to about 20 years. In some embodiments, the long duration is greater than about 20 years.

[0117] In some embodiments, the elevated pressure or differential pressure is in a range of from about 100 kPa to about 10000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 100 kPa to about 8000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 100 kPa to about 5000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 100 kPa to about 2000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 1000 kPa to about 10000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about1000 kPa to about 8000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 1000 kPa to about 5000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 1000 kPa to about 2000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 2000 kPa to about 10000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 2000 kPa to about 8000 kPa. In some embodiments, the elevated pressure or differential pressure is in a range of from about 2000 kPa to about 5000 kPa.

[0118] In some embodiments, the temperature or differential temperature is in a range of from about 20 °C to about 120 °C. In some embodiments, the temperature or differential temperature is in a range of from about 20 °C to about 80 °C. In some embodiments, the temperature or differential temperature is in a range of from about 20 °C to about 60 °C. In some embodiments, the temperature or differential temperature is in a range of from about 20 °C to about 40 °C. In some embodiments, the temperature or differential temperature is in a range of from about 40 °C to about 120 °C. In some embodiments, the temperature or differential temperature is in a range of from about 40 °C to about 80 °C. In some embodiments, the temperature or differential temperature is in a range of from about 20 °C to about 60 °C. In some embodiments, the temperature or differential temperature is in a range of from about 60 °C to about 80 °C.

[0119] In some embodiments, the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of membranes, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

[0120] In some embodiments, the first surface and the second surface are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0121] In some embodiments, the product is selected from the group consisting of stacks, fuel cells, fuel cell stacks, batteries, flow batteries, electrolyzers, water electrolyzers, and combinations thereof.

[0122] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0123] 1. A composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component.

[0124] 2. The composite according to the preceding clause, wherein the first material is selected from the group consisting of porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC). poly sulfone, poly ethersulfone, poly phenylsulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treated versions thereof, mixtures thereof, and combinations thereof.

[0125] 3. The composite according to any preceding clause, wherein the fluid-permeable portion is selected from the group consisting of pores, grooves, ridges, divots, indentations, holes, through-holes, and combinations thereof.

[0126] 4. The composite according to any preceding clause, wherein the second material is selected from the group consisting of hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fluorinated polymer electrolytes, ionomers, cationic exchange polymers, anionic exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene based fluoropolymer-copolymers, perfluorosulfonic acid (PFSA) polymers, copolymers thereof, sulfonate salts thereof, and combinations thereof.

[0127] 5. The composite according to any preceding clause, wherein the interface is formed by a method comprising: receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and solidifying the liquid component in the fluid-permeable portion of the first material.

[0128] 6. The composite according to any preceding clause, wherein the composite is in a form selected from the group consisting of films, tapes, welding tapes, welding mediators, sheets, blocks, bars, rods, tubes, and combinations thereof.

[0129] 7. The composite according to any preceding clause, wherein the first component and the second component are coupled at the interface by mechanical interlocking.

[0130] 8. A product comprising the composite according to any preceding clause, wherein the composite couples a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

[0131] 9. The product according to the preceding clause, wherein the product is configured to be used for long durations at an elevated pressure and / or a temperature.

[0132] 10. The product according to any preceding clause, wherein the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

[0133] 11. The product according to any preceding clause, wherein the membranes, diaphragms, and separators further comprise a reinforcement material.

[0134] 12. The product according to the preceding clause, wherein the reinforcement material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or a combination thereof.

[0135] 13. The product according to any preceding clause, wherein the product is selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfacesof separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

[0136] 14. A membrane electrode assembly (MEA) comprising the composite according to any preceding clause.

[0137] 15. A method of making a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and solidifying the liquid component in the fluid-permeable portion of the first material.

[0138] 16. The method according to the preceding clause, wherein the liquid component is received in the fluid-permeable portion of the first material upon application of the liquid component with a technique selected from the group consisting of coating, slot die coating, doctor blade coating, rod coating, Mayer rod coating, gravure coating, electrocoating, dipping, spraying, and combinations thereof.

[0139] 17. The method according to any preceding clause, wherein the liquid component is received in the fluid-permeable portion of the first material at a temperature less than about 50 °C.

[0140] 18. The method according to any preceding clause, wherein solidifying the liquid component in the fluid-permeable portion of the first material comprises drying the liquid component.

[0141] 19. A method of using a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: using the composite to couple a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

[0142] 20. The method according to the preceding clause, wherein the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow' plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

[0143] 21. The product according to any preceding clause, wherein the membranes, diaphragms, and separators further comprise a reinforcement material.

[0144] 22. The product according to the preceding clause, wherein the reinforcement material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or a combination thereof.

[0145] 23. The method according to any preceding clause, wherein each of the first surface and the second surface are coupled to the composite with a w elding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0146] 24. A membrane electrode assembly (MEA), comprising: a membrane; at least one electrocatalyst layer disposed on a side of the membrane; optionally at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component; wherein the composite is coupled to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from surfaces of the membrane, surfaces of gaskets, surfaces of sealing gaskets, surfaces of the at least one electrocatalyst layer, surfaces of the at least one gas diffusion substrate and / or porous transport layer, surfaces of electrolyzers, and combinations thereof.

[0147] 25. The MEA according to the preceding clause, wherein the first surface and / or the second surface are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0148] 26. The MEA according to any preceding clause, wherein the at least one electrocatalyst layer comprises two electrocatalyst layers, wherein the two electrocatalyst layers are disposed on different sides of the membrane.

[0149] 27. The MEA according to any preceding clause, wherein the at least one gas diffusion substrate comprises two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

[0150] 28. The MEA according to any preceding clause, wherein the composite is in contact with an edge of each of the two electrocatalyst layers and / or at least one gas diffusion substrate and / or porous transport layer.

[0151] 29. An assembly comprising: at least one sealing gasket comprising a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and the MEA of any preceding clause; wherein the composite is coupled to the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket.

[0152] 30. The assembly according to the preceding clause, wherein the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

[0153] 31. The assembly according to any preceding clause, comprising at least two sealing gaskets, wherein each of the at least two sealing gaskets are coupled to the composite.

[0154] 32. The assembly according to any preceding clause, wherein the assembly is a sealed assembly.

[0155] 33. A product comprising the assembly according to any preceding clause.

[0156] 34. The product according to the preceding clause, wherein the product is configured to be used for long durations at an elevated pressure and / or a temperature.

[0157] 35. The product according to any preceding clause, wherein the product is selected from the group consisting of stacks, fuel cells, fuel cell stacks, batteries, flow batteries, electrolyzers, water electrolyzers, and combinations thereof.EXAMPLES

[0158] Without further elaboration, it is believed that one skilled in the art using the preceding description can utilize the present invention to its fullest extent. The following Examples are. therefore, to be construed as merely illustrative, and not limiting of the disclosure in any way whatsoever. The starting material for the following Examples may not have necessarily been prepared by a particular preparative run whose procedure is described in other Examples. It also is understood that any numerical range recited herein includes all values from the lower value to the upper value. For example, if a range is stated as 10-50, it is intended that values such as 12-30, 20-40, or 30-50, etc., are expressly enumerated in this specification. These are only examples of what is specifically intended, and all possible combinations of numerical values between and including the lowest value and the highest value enumerated are to be considered to be expressly stated in this application.

[0159] Test Method - Adhesion

[0160] A custom welding system was used to demonstrate the performance of composite materials as weldable gaskets. The system used a weld bar with a contact area of 1.5 square inches. The materials were placed under the weld bar in the orientation described hereafter. The composite was placed between the PFSA material and the non-porous PE base, such that the porous layer of the composite was in contact with the nonporous base plate and the PFSA surface of the composite was in contact with the PFSA material. A protective ePTFE sheet was used to separate the PFSA surface from the weld bar. The materials were pressed at 120 kPa and 180 °C for 2 minutes. A Thwing- Albert Precision Sample cutter was used to cut the samples into 1-inch strips. Before testing, the thickness of the weld area was measured for each strip using the Mituoyo Drop Gauge Thickness Tester. Three points were measured across the weld area. The average was taken and recorded in the Instron software.

[0161] Before testing, the Instron load cell w as calibrated. Force and displacement were balanced before loading the sample. The gauge length was set at two inches. ASTM D882 for thin plastic films was the method used for testing. The sample was placed in the jaw faces using tweezers and secured using the pneumatic grips at a pressure of 40 psi. Adjustments w ere made as needed to ensure the sample was straight and in line w ith the grip faces. Once secure, the test was run at a strain rate of 500 mm / min until sample break. After testing, the sample was removed and the crosshead was returned to a gauge length of two inches. The instrument w as rebalanced before repeating the procedure for additional samples.Example 1. Composite.

[0162] In this exemplary' embodiment, a composite in accordance with the present disclosure is demonstrated.

[0163] A composite in accordance with the present disclosure was prepared by coating a Nation™ (PFSA polymer) polymer dispersion (10% solid by weight in water / alcohol mixture, 1000 EW) on a porous PE substrate filled with silica particles with a slot die coater. The coated substrate was dried at 120 °C with 4 minutes of residence time. The nominal thickness of the porous PE was 160 pm. The nominal thickness of the Nafion™ polymer layer after drying was 10 pm. During the coating process, the Nafion™ polymer partially penetrated pores of the PE substrate to form a domain including mechanical entanglement between the Nafion™ polymer and the PE substrate. This mechanical entanglement provided good adhesion to form the composite. The composite included a first layer of Nafion™ polymer, a second layer of PE, and a third layer of the mechanically entangled Nafion™ polymer and PE layer that separated the first layer and the second layer.Example 2. Composite.

[0164] In this exemplary' embodiment, a composite in accordance with the present disclosure is demonstrated.

[0165] A composite in accordance with the present disclosure was prepared according to the method described in Example 1, except that the PE layer was replaced by Celgard 5550. Celgard 5550 is a 25 pm monolayer microporous PP laminated to a PP non-woven fabric. The non-woven side was coated with the Nafion™ (PFSA polymer) polymer dispersion (10% solid by weight in water / alcohol mixture, EW 1000) using a doctor blade coater. During the coating process, the Nafion™ polymer partially penetrated pores of the PP substrate to form a domain including mechanical entanglement between the Nafion™ polymer and the PP substrate. This mechanical entanglement provided good adhesion to form the composite. The composite included a first layer of Nafion™ polymer, a second layer of PP, and a third layer of the mechanically entangled Nafion™ polymer and PP layer that separated the first layer and the second layer.Example 3. Composite.

[0166] In this exemplary' embodiment, a composite in accordance with the present disclosure is demonstrated.

[0167] A composite in accordance with the present disclosure was prepared according to the method described in Example 1, except that the PE layer was replaced by Celgard 3420 and a doctor blade coater was used instead of slot die. Celgard 3420 is a monolayer nonwoven PP separator. The non-woven PP separator substrate was wetted by soaking in water and then coated with theNafion™ (PFSA polymer) polymer dispersion (10% solid by weight in water / alcohol mixture, EW 1000) using a doctor blade coater. During the coating process, the Nafion™ polymer partially penetrated pores of the PP substrate to form a domain including mechanical entanglement between the Nafion™ polymer and the PP substrate. This mechanical entanglement provided good adhesion to form the composite. The composite included a first layer of Nafion™ polymer, a second layer of PP, and a third layer of the mechanically entangled Nafion™ polymer and PP layer that separated the first layer and the second layer.Example 4. Composite.

[0168] In this exemplary’ embodiment, a composite in accordance with the present disclosure is demonstrated.

[0169] A composite in accordance with the present disclosure was prepared according to the method described in Example 1 , except that the PE layer was replaced by Cobetter PHI DT porous separator and a doctor blade coater was used instead of slot die. Cobetter PH1DT is a bilayer separator including an ePTFE layer supported on non-woven PP layer. During the coating process, the Nafion™ polymer partially penetrated pores of the ePTFE surface to form a domain including mechanical entanglement between the Nafion™ polymer and Cobetter PH1DT. This mechanical entanglement provided good adhesion to form the composite. The composite included a first layer of Nafion™ polymer, a second layer of ePTFE, and a third layer of the mechanically entangled Nafion™ polymer and ePTFE layer that separated the first layer and the second layer. The composite also included a fourth layer of non-woven PP attached ePTFE.Example 5. Coupled surfaces.

[0170] In this exemplary embodiment, it is demonstrated that composites in accordance with the present disclosure may be used to bond surfaces including incompatible polymers and / or other incompatible materials.

[0171] The composite of Example 1 was used to couple a Nafion™ N115 (PFSA polymer) membrane base to a non-porous PE base. In an inventive test, the composite ofExample 1 was placed between the PFSA base plate and a non-porous PE base plate such that the porous PE layer of the composite was in contact with the non-porous PE base plate and the PFSA surface of the composite was in contact with the PFSA base plate. There was very strong adhesion after pressing at 120 kPa (weld foot contact area of 0.375 in2) and 180 °C for 2 minutes.

[0172] The strength of the bond between the base plates in the inventive example w as measured by a tensile tester. It was surprisingly discovered that the PE / PFSA strip coupled by the composite was pulled from the ends of base plates at a maximum tensile stress of 25.6 ± 0.6 MPa. The tensile strength of PFSA by itselfis 27.9 ± 1.1 MPa. Although it was expected that the composite would exhibit very weak tensile strength compared to conventional welding techniques, it was unexpectedly found that the performance of the composite was close to that of PFSA by itself. The data show that the composite enables complete coupling of two incompatible polymer surfaces and provides enhanced adhesion.Example 6. Coupled surfaces.

[0173] In this exemplary embodiment, it is demonstrated that composites in accordance with the present disclosure may be used to bond surfaces including incompatible polymers and / or other incompatible materials.

[0174] The composite of Examples 2-4 were each used to couple aNafion™N115 (PFSA polymer) membrane base to a non-porous PE base according to the method described in Example 5.

[0175] Very7strong adhesion w as observed for each of the composites of Examples 2-4 after pressing at 120 kPa (weld foot contact area of 0.375 in2) and 180 °C for 2 minutes. Further, the strength of the bond between the base plates in the inventive example was measured by a tensile tester. It was surprisingly discovered that the PE / PFSA strip coupled by the composite was pulled from the ends of base plates at a high tensile strength close to that of PFSA by itself. The data show' that the composite enables complete coupling of two incompatible polymer surfaces and provides enhanced adhesion.Comparative Example 1. Coupled surfaces.

[0176] In this comparative example, it is demonstrated that surfaces including incompatible polymers and / or other incompatible materials cannot be bonded without composites in accordance with the present disclosure.

[0177] In a first control test, there was no adhesion when only PFSA and non-porous PE base plates were pressed at 120 kPa (weld foot contact area of 0.375 in2) and 180 °C for 2 minutes.Comparative Example 2. Coupled surfaces.

[0178] In this comparative example, it is demonstrated that surfaces including incompatible polymers and / or other incompatible materials cannot be bonded without composites in accordance with the present disclosure.

[0179] In a second control test, there was no adhesion when only PFSA and porous PE base plates were pressed at 120 kPa (weld foot contact area of 0.375 in2) and 180 °C for 2 minutes.Example 7. Weldable gasket.

[0180] In this exemplary embodiment, it is demonstrated that composites in accordance with the present disclosure may be used as weldable gaskets.

[0181] The composite of Example 1 was used as a weldable gasket to seal a half membrane electrode assembly (MEA), where the weldable gasket was only applied to one side of a membrane. The MEA was made from 15 pm thick PFSA membrane. A weldable gasket according to Example 1 was aligned on one side of the membrane to cover only the periphery of the membrane, where the polymer electrolyte surface of the weldable gasket touched the edges of the membrane. The gasket and the membrane were simultaneously hot pressed at 140 °C for 7 min between 8"x8” steel plates. The force was 3000 lbs. The pressure was maintained until the plate temperatures dropped below 40 °C. This resulted in a welded MEA.

[0182] A test cell was designed to stress the sealing area between the test gasket and membrane. A second gasket was placed against the test assembly made from the test gasket such that the membrane was not in contact with the second gasket. The test design did not provide any support to the junction between the test gasket and the membrane.

[0183] The test assembly was placed between two plates with flow channels. One standard liter per minute of dry nitrogen gas at ambient temperature was flowed into half of the cell for 3 minutes. The outlet of the other half of the cell was observed for leaks. If no or infrequent bubbles were observed, the pressure applied to the nitrogen flowing into the cell was increased and the 3 -minute hold was repeated.

[0184] No gas flow or bubbling was observed in the test assembly until 150 kPa. Between 150 kPa and 200 kPa, there was slow bubbling, with 10-15 seconds per bubble. Between 250 kPa and 300 kPa, there was moderate bubbling, with 5-10 seconds per bubble. At 345 kPa, there was moderate bubbling, with 3-5 seconds per bubble.Comparative Example 3. Weldable gasket.

[0185] In this comparative example, it is demonstrated that composites not in accordance with the present disclosure may not be used as weldable gaskets.

[0186] A control test MEA was also fabricated via a similar process as Example 5, except a standard gasket material (polyethylene) was used instead of the weldable gasket. The PE gasket was used as a gasket to seal a half membrane electrode assembly (MEA), where the PE gasket was only applied to one side of a membrane. The MEA was made from 15 pm thick PFSA membrane. A PE gasket was aligned on one side of the membrane to cover only the periphery of the membrane. The PE gasket and the membrane were simultaneously hot pressed at 140 °C for 7 min between 8”x8” steel plates. The force was 3000 lbs. The pressure was maintained until the plate temperatures dropped below 40 °C. This resulted in a comparative MEA.

[0187] The test assembly was placed between two plates with flow channels. One standard liter per minute of dry nitrogen gas at ambient temperature was flowed into half of the cell for 3 minutes. The outlet of the other half of the cell was observed for leaks. If no or infrequent bubbles were observed, the pressure applied to the nitrogen flowing into the cell was increased and the 3 -minute hold was repeated.

[0188] The test assembly made with the control gasket had visible bubbles flowing from the cell into a water trap. Rapid bubbling was observed, with less than one second per bubble.Example 8. Composite

[0189] Example 4 w as repeated, using Cobetter P04HZ instead of Cobetter PH1DT.Example 9. Coupled surfaces

[0190] Example 6 was repeated, using the composite of Example 2 to couple PFSA to non-porous polypropylene.Example 10. Coupled surfaces

[0191] Example 6 was repeated, using the composite of Example 3 to couple PFSA to non-porous polypropylene.Example 11. Coupled surfaces

[0192] Example 6 was repeated, using the composite of Example 4 to couple PFSA to non-porous polypropylene.Example 12. Coupled surfaces

[0193] Example 6 was repeated, using the composite of Example 8 to couple PFSA to non-porous polypropylene.Comparative Example 4

[0194] Example 5 was repeated, using a porous PE substrate filled with silica particles between the PFSA and non-porous PE layers instead of the composite interface.Comparative Example 5

[0195] Example 9 was repeated, using Celgard 5550 between the PFSA and non-porous polypropylene layers instead of the composite interface.Comparative Example 6

[0196] Example 10 was repeated, using Celgard 3420 between the PFSA and non-porous polypropylene layers instead of the composite interface.Comparative Example 7

[0197] Example 12 was repeated, using Cobetter P04HZ between the PFSA and non- porous polypropylene layers instead of the composite interface.Table 1. Adhesion of Coupled SurfacesConclusions

[0198] It was surprisingly discovered in the present disclosure that a composite including incompatible polymers and / or other incompatible materials could be produced by coupling the incompatible polymers and / or other incompatible materials with an interface including one material contained in a fluid-permeable portion of another material. Such composites unexpectedly demonstrate improved tensile strength and adhesion. They are useful in a wide variety7of applications that require the coupling of incompatible polymers and / or other incompatible materials. They are particularly useful in applications that require the coupling of incompatible polymers and long-term exposure to elevated temperatures and / or elevated pressures.

[0199] This written description uses examples to illustrate the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any compositions or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have elements that do not differ from the literal language of the claims, or if they include equivalent elements with insubstantial differences from the literal language of the claims.

[0200] As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains”, “containing,” “characterized by” or any other variation thereof, are intended to cover a non-exclusive inclusion, subject to any limitation explicitly indicated. For example, a composition, mixture, process or method that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such composition, mixture, process or method.

[0201] The transitional phrase “consisting of’ excludes any element, step, or ingredient not specified. If in the claim, such would close the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase “consisting of’ appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0202] The transitional phrase “consisting essentially of’ is used to define a composition or method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention. The term “consisting essentially of’ occupies a middle ground between “comprising"’ and “consisting of’.

[0203] Where an invention or a portion thereof is defined with an open-ended term such as “comprising,” it should be readily understood that (unless otherwise stated) the description should be interpreted to also describe such an invention using the terms "‘consisting essentially of’ or “consisting of.”

[0204] Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0205] Also, the indefinite articles “a” and “an” preceding an element or component of the invention are intended to be nonrestrictive regarding the number of instances (i.e. occurrences) of the element or component. Therefore "‘a” or “an” should be read to include one or at least one, and the singular word form of the element or component also includes the plural unless the number is obviously meant to be singular.

[0206] As used herein, the term “about” means plus or minus 10% of the value.

Claims

WHAT IS CLAIMED IS:

1. A composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component.

2. The composite of claim 1 , wherein the first material is selected from the group consisting of porous polymer materials, polyolefins, aromatic hydrocarbon polymers, polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), polyvinyl chloride (PVC), polysulfone, poly ethersulfone, polyphenylsulfone, polyphenylene sulfide (PPS), poly(aryl ether sulfone), polystyrene, polyethylene oxide, copolymers thereof, hydrophilic treated versions thereof, mixtures thereof, and combinations thereof.

3. The composite of claim 1, wherein the fluid-permeable portion is selected from the group consisting of pores, grooves, ridges, divots, indentations, holes, through-holes, and combinations thereof.

4. The composite of claim 1, wherein the second material is selected from the group consisting of hydrocarbon polymer electrolytes, partially fluorinated polymer electrolytes, fluorinated polymer electrolytes, ionomers, cationic exchange polymers, anionic exchange polymers, sulfonated tetrafluoroethylene polymers, sulfonated tetrafluoroethylene based fluoropoly mer-copolymers, perfluorosulfonic acid (PF SA) polymers, copolymers thereof, sulfonate salts thereof, and combinations thereof.

5. The composite of claim 1, wherein the interface is formed by a method comprising: receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; andsolidifying the liquid component in the fluid-permeable portion of the first material.

6. The composite of claim 1, wherein the composite is in a form selected from the group consisting of films, tapes, welding tapes, welding mediators, sheets, blocks, bars, rods, tubes, and combinations thereof.

7. The composite of claim 1, wherein the first component and the second component are coupled at the interface by mechanical interlocking.

8. A product comprising the composite of claim 1. wherein the composite couples a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

9. The product of claim 8, wherein the product is configured to be used for long durations at an elevated pressure and / or a temperature.

10. The product of claim 8, wherein the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of w ater electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of membranes, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

11. The product according to claim 10, wherein the membranes, diaphragms, and separators further comprise a reinforcement material.

12. The product according to claim 11, wherein the reinforcement material is PTFE, ePTFE, PEEK, PES. PE, PP, PPS. or a combination thereof.

13. The product of claim 8, wherein the product is selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts,surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

14. A membrane electrode assembly (MEA) comprising the composite of claim 1.

15. A method of making a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: receiving a liquid component comprising the second material and a liquid carrier in the fluid-permeable portion of the first material; and solidifying the liquid component in the fluid-permeable portion of the first material.

16. The method of claim 15, wherein the liquid component is received in the fluid- permeable portion of the first material upon application of the liquid component with a technique selected from the group consisting of coating, slot die coating, doctor blade coating, rod coating. Mayer rod coating, gravure coating, electrocoating, dipping, spraying, and combinations thereof.

17. The method of claim 15, wherein the liquid component is received in the fluid- permeable portion of the first material at a temperature less than about 50 °C.

18. The method of claim 15, wherein solidifying the liquid component in the fluid- permeable portion of the first material comprises drying the liquid component.

19. A method of using a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; anda second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component, wherein the method comprises: using the composite to couple a first surface comprising a material compatible with the first material and a second surface comprising a material compatible with the second material.

20. The method of claim 19, wherein the first surface and / or the second surface are each selected from the group consisting of surfaces of membranes, surfaces of diaphragms, surfaces of separators, surfaces of fuel cells, surfaces of fuel cell stacks, surfaces of batteries, surfaces of flow batteries, surfaces of electrolyzers, surfaces of water electrolyzers, surfaces of electrodes, surfaces of cathodes, surfaces of anodes, surfaces of membrane electrode assemblies, surfaces of catalysts, surfaces of field flow plates, surfaces of gaskets, surfaces of sealing gaskets, surfaces of membranes, surfaces of gas diffusion substrates, surfaces of gas diffusion electrodes, surfaces of porous transport layers, catalyst coated membranes, and combinations thereof.

21. The product according to claim 20, wherein the membranes, diaphragms, and separators further comprise a reinforcement material.

22. The product according to claim 21, wherein the reinforcement material is PTFE, ePTFE, PEEK, PES, PE, PP, PPS, or a combination thereof.

23. The method of claim 19. wherein each of the first surface and the second surface are coupled to the composite with a w elding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

24. A membrane electrode assembly (MEA), comprising: a membrane; at least one electrocatalyst layer disposed on a side of the membrane; optionally at least one gas diffusion substrate and / or porous transport layer in physical contact with the at least one electrocatalyst layer; and a composite comprising: a first component comprising a first material comprising a fluid-permeable portion; and a second component comprising a second material incompatible with the first material; wherein the first component and the second component are coupled at an interface comprising the second material contained in the fluid-permeable portion of the first material; and wherein the interface forms a third component that separates at least a portion of the first component from the second component; wherein the composite is coupled to a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and wherein the first surface and / or the second surface are each selected from surfaces of the membrane, surfaces of gaskets, surfaces of sealing gaskets, surfaces of the at least one electrocatalyst layer, surfaces of electrolyzers, surfaces of the at least one gas diffusion substrate and / or porous transport layer, and combinations thereof.

25. The MEA of claim 24. wherein the first surface and / or the second surface are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

26. The MEA of claim 24, wherein the at least one electrocatalyst layer comprises two electrocatalyst layers, wherein the two electrocatalyst layers are disposed on different sides of the membrane.

27. The MEA of claim 24, wherein the at least one gas diffusion substrate comprises two gas diffusion substrates, wherein the two gas diffusion substrates are in physical contact with different electrocatalyst layers.

28. The MEA of claim 24, wherein the composite is in contact with an edge of each of the two electrocatalyst layers and / or at least one gas diffusion substrate and / or porous transport layer.

29. An assembly comprising: at least one sealing gasket comprising a first surface comprising a material compatible with the first material and / or a second surface comprising a material compatible with the second material; and the MEA of claim 24; wherein the composite is coupled to the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket.

30. The assembly of claim 29, wherein the first surface of the at least one sealing gasket and / or the second surface of the at least one sealing gasket are each coupled to the composite with a welding technique selected from the group consisting of ultrasonic welding, hot-gas welding, speed-tip welding, injection welding, vibration welding, laser welding, spin welding, infrared welding, induction welding, high frequency welding, friction welding, contact welding, extrusion welding, hot plate welding, and combinations thereof.

31. The assembly of claim 29, comprising at least two sealing gaskets, wherein each of the at least two sealing gaskets are coupled to the composite.

32. The assembly of claim 29, wherein the assembly is a sealed assembly.

33. A product comprising the assembly of claim 29.

34. The product of claim 33. wherein the product is configured to be used for long durations at an elevated pressure and / or a temperature.

35. The product of claim 33, wherein the product is selected from the group consisting of stacks, fuel cells, fuel cell stacks, batteries, flow batteries, electrolyzers, water electrolyzers, and combinations thereof.

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