Composite Membrane With Continuous Ionomer Phase Against Blistering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional ionomer film composite membranes used in flow batteries suffer from premature structural failure due to the formation of bubbles or blisters at internal interfaces between ionomer layers, leading to reduced mechanical strength, high in-plane swelling, and increased crossover of reactive species.
Innovation Solution
The development of composite membranes with a continuous ionomer phase, achieved through a single or multiple pass ionomer coating process without drying between layers, which eliminates internal interfaces and enhances mechanical strength, ion conductance, and reduces swelling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coatings of ionomer are used to form composite membranes, then ion conductance is improved, but structural failure occurs due to bubble or blister formation at internal interfaces
Solution Approach 1:
The patent merges multiple ionomer coatings into a single continuous ionomer phase by eliminating the drying step between coatings. This allows the ionomer to form a unified, interface-free structure that maintains structural integrity while providing the desired ion conductance, resolving the contradiction between reliability and structural complexity.
Solution Approach 2:
The patent ensures continuous ionomer phase formation by applying subsequent coatings immediately without drying interruptions. This continuity prevents the formation of internal interfaces and blisters, maintaining structural reliability while achieving the cumulative ion conductance benefits of multiple layers.
2Strength
If multiple coatings of ionomer are applied with drying between layers, then manufacturing process is simplified, but mechanical strength decreases due to internal interface formation
Solution Approach 1:
The patent maintains continuous ionomer phase formation by eliminating drying steps between coatings, preventing internal interface formation and preserving mechanical strength. The process complexity is managed through streamlined sequential coating application rather than traditional multi-step drying and coating cycles.
3Stability of the object's composition
If traditional ionomer film composite membranes are used, then ease of manufacture is improved, but in-plane swelling increases leading to reduced performance
Solution Approach 1:
The patent combines multiple ionomer coatings into a single continuous phase, eliminating internal interfaces that cause differential swelling. This unified structure maintains dimensional stability and reduces in-plane swelling, improving compositional stability while managing structural complexity through phase continuity.
4Reliability
If discontinuous ionomer phase is used in composite membranes, then manufacturing is easier, but crossover of reactive species increases
Solution Approach 1:
The patent merges multiple ionomer coatings into a continuous phase that eliminates internal interfaces and defects. This continuous structure provides superior crossover resistance by preventing pathways for reactive species penetration, while the manufacturing complexity is reduced through elimination of drying steps between coatings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The continuous ionomer phase membranes exhibit zero blister formation and minimal haze change after a blister test, maintaining structural integrity and performance in flow batteries.
Implementation Method 1
an ion exchange material at least partially embedded within the microporous polymer structure and rendering at least a portion of the microporous polymer structure occlusive. The ion exchange material forms a continuous ionomer phase within the composite membrane.
Implementation Method 2
The composite membrane exhibits a haze change of 0% or less after being subjected to a blister test procedure. The blister test procedure may include at step one immersing the composite membrane for 3 minutes in an 6 mol/L aqueous sulfuric acid solution at 80° C.
Data Source
AI summary
Embodiments are directed to composite membranes having a microporous polymer structure, and an ion exchange material forming a continuous ionomer phase within the composite membrane. The continuous ionomer phase refers to absence of any internal interfaces in a layer of ionomer or between any number of layers coatings of the ion exchange material provided on top of one another. The composite membrane exhibits a haze change of 0% or less after being subjected to a blister test procedure. No bubbles or blisters are formed on the composite membrane after the blister test procedure. A haze value of the composite membrane is between 5% and 95%, between 10% and 90% or between 20% and 85%. The composite membrane may have a thickness of more than 17 microns at 0% relative humidity.