Composite Electrochemical Membrane for Piercing-Resistant PEMs

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Solution Overview

Problem

Existing polymer electrolyte membranes (PEMs) in electrochemical devices face issues with low mechanical durability and susceptibility to piercing, leading to potential failure and shorting, particularly in redox flow batteries, due to conflicts in optimizing selectivity, conductance, and cost.

Innovation Solution

A composite membrane design with at least two reinforcing layers of microporous polymer structure, distributed across the membrane, enhances piercing resistance without increasing thickness or ionomer amount, using a microporous polymer structure content of at least 20 vol% and maintaining a thickness of at least 10 μm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the PEM thickness is reduced to improve selectivity and reduce cost, then proton conduction increases and cost decreases, but mechanical strength decreases and susceptibility to piercing increases

Engineering Contradiction:

ImproveselectivityVSAvoidmechanical durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs a composite membrane structure combining a thin PEM layer (for high proton conduction and selectivity) with a microporous reinforcement layer (for mechanical strength and piercing resistance). This composite approach allows the membrane to achieve both high reliability in terms of selectivity and adequate mechanical strength, resolving the contradiction between thinning the membrane and maintaining durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement layer uses a microporous polymer structure with controlled porosity (30-80% pore volume) to provide mechanical support while maintaining ion transport capability. The porous structure allows protons to pass through while the rigid framework prevents piercing, addressing both the selectivity and strength requirements.

Inventive Principle:

Principle #31Porous materials

2Ease of manufacture

If the PEM thickness is reduced to reduce ionomer usage and cost, then material cost decreases, but resistance to piercing by electrode components increases

Engineering Contradiction:

ImprovecostVSAvoidpiercing susceptibility

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The composite structure combines a thin, low-cost PEM layer with a microporous reinforcement layer that acts as a protective barrier against piercing by carbon fibers and other electrode components. This allows cost reduction through thinner PEM while maintaining resistance to mechanical damage from assembly components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The microporous reinforcement layer serves as a pre-established protective barrier that cushions and distributes mechanical stresses from electrode compression and assembly components before they can penetrate the thin PEM layer, preventing piercing failures during device assembly and operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If a single reinforcing layer is used to simplify structure, then device complexity decreases, but piercing resistance is insufficient

Engineering Contradiction:

ImprovestructureVSAvoidpiercing resistance

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The reinforcement function is segmented into multiple discrete layers rather than using a single thick layer. The microporous reinforcement layer is divided into multiple sub-layers (first, second, and third microporous layers) that work together to provide enhanced piercing resistance while maintaining a relatively simple overall structure and allowing ion transport.

Inventive Principle:

Principle #1Segmentation

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 composite membrane exhibits superior resistance to piercing by electrochemical device components, reducing the risk of failure and shorting, while maintaining high performance and low ionic resistance.

Implementation Method 1

an ion exchange material (IEM) at least partially imbibed within the microporous polymer structure of the at least two reinforcing layers

Methodology Applied

Scientific EffectIon Exchange: Ion Exchange

Implementation Method 2

Methodology Applied

Scientific EffectIon Conduction: Conduction (electrical)

Data Source

PatentUS12580214B2Electrochemical membrane

Publication Date: 2026.03.17 WL GORE & ASSOC INC

AI summary

This disclosure relates to polymer electrolyte membranes, and in particular, to a composite membrane having at least two reinforcing layers comprising a microporous polymer structure and a surprisingly high resistance to piercing. This disclosure also relates to composite membrane-assemblies and electrochemical devices comprising the composite membranes of the disclosure, and to methods of manufacture of the composite membranes.