Fluorinated Polymer Pellet Extrusion for Stable Electrolysis Voltage
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Solution Overview
Problem
Existing ion exchange membranes exhibit large variations in electrolysis voltage, which affects production efficiency, when using pellets of fluorinated polymers with high ion exchange capacity.
Innovation Solution
The method involves extruding a melt of fluorinated polymer with convertible ion exchange groups at a die temperature below 200°C and converting these groups to ion exchange groups with a capacity of at least 1.1 meq/g resin, resulting in pellets with a light transmittance of 30-60%, which suppresses aggregation and pressure variation during film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pellets of fluorinated polymer with high ion exchange capacity are used, then ion exchange capacity is improved, but electrolysis voltage stability deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the die temperature during pellet extrusion (maintaining it below 200°C) and specifying the ion exchange capacity range (1.1-2.0 meq/g). These parameter adjustments optimize the pellet structure to achieve both high ion exchange capacity and stable electrolysis voltage, resolving the contradiction between quantity of substance and reliability.
2Ease of manufacture
If die temperature is increased to improve extrusion, then extrusion ease is improved, but film thickness uniformity deteriorates
Solution Approach 1:
The patent specifies a precise temperature parameter for the die (below 200°C) that balances extrusion ease with film thickness uniformity. This controlled temperature parameter prevents excessive melting that would cause aggregation while ensuring sufficient flowability for uniform extrusion, thereby resolving the contradiction between ease of manufacture and manufacturing precision.
3Quantity of substance
If ion exchange capacity is increased, then ion exchange performance is improved, but pressure variation during film formation increases
Solution Approach 1:
The patent resolves this contradiction by controlling two key parameters: the die temperature (below 200°C) and the ion exchange capacity (1.1-2.0 meq/g). The controlled die temperature prevents excessive softening and aggregation of high ion exchange capacity pellets during extrusion, thereby reducing pressure variation while maintaining high ion exchange performance.
4Ease of manufacture
If pellets aggregate during film formation, then film formation ease deteriorates, but film thickness uniformity deteriorates
Solution Approach 1:
The patent addresses pellet aggregation by controlling the die temperature (below 200°C) and ion exchange capacity (1.1-2.0 meq/g). These parameter controls optimize the pellets' physical properties to prevent aggregation during film formation, ensuring both ease of manufacture and uniform film thickness.
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
This approach produces an ion exchange membrane with improved stability and uniformity in electrolysis voltage, reducing deviations and enhancing film thickness consistency.
Implementation Method 1
The temperature of the die when the melt containing the fluorinated polymer is extruded from the die is less than 200° C.
Implementation Method 2
when the groups convertible to ion exchange groups of the fluorinated polymer are converted to ion exchange groups, the ion exchange capacity of the resulting fluorinated polymer is at least 1.1 meq/g resin
Data Source
AI summary
To provide a method for producing pellets from which an ion exchange membrane excellent in stability of the electrolysis voltage can be formed, pellets, and an ion exchange membrane.The method for producing pellets of the present invention is a method for producing pellets, which comprises extruding a melt containing a fluorinated polymer having groups convertible to ion exchange groups from a die of a melt-extruder to obtain a strand containing the fluorinated polymer, and cutting the strand to obtain pellets containing the fluorinated polymer,wherein the temperature of the die when the melt containing the fluorinated polymer is extruded from the die is less than 200° C., andwhen the groups convertible to ion exchange groups of the fluorinated polymer are converted to ion exchange groups, the ion exchange capacity of the resulting fluorinated polymer is at least 1.1 milliequivalent/g dry resin.