Fluoropolymer Hybrid Electrolyte Membrane With Uniform Ion Pathways
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Solution Overview
Problem
Existing methods for manufacturing fluoropolymer hybrid organic/inorganic composites face challenges such as low ionic conductivity due to limited electrolyte interpenetration in films, non-homogeneous atomic distribution, and the use of undesirable organic solvents, which complicates industrial processing.
Innovation Solution
A process involving a pre-gelled metal compound reacted with a functional fluoropolymer in the molten state, using an electrolyte solution and an acid catalyst, avoids solvent casting and achieves a fluoropolymer hybrid composite with improved atomic homogeneity and high conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If films are casted and then swelled with electrolyte solution, then the film structure is formed, but the amount of electrolyte interpenetrated is relatively low resulting in low ionic conductivity
Solution Approach 1:
The electrolyte solution is incorporated into the hybrid composite during the sol-gel reaction process itself, before the film is casted. This preliminary incorporation ensures that the electrolyte is uniformly distributed throughout the film structure from the beginning, eliminating the need for subsequent swelling steps and achieving high ionic conductivity.
Solution Approach 2:
The process merges the film formation step with the electrolyte incorporation step into a single simultaneous operation. The electrolyte solution is present during the sol-gel reaction and hydrolysis-polycondensation process, combining multiple functions into one integrated process that produces films with high electrolyte content and good ionic conductivity.
2Ease of manufacture
If casting technique is used to prepare films, then films can be obtained, but organic solvents like NMP and DMA must be used which are undesirable in industrial production
Solution Approach 1:
The harmful organic solvents (NMP, DMA) are extracted/removed from the process by replacing them with water as the processing medium. The sol-gel reaction and film formation are achieved using aqueous solutions, eliminating the need for undesirable organic solvents while maintaining ease of film preparation.
Solution Approach 2:
The process changes the key parameter of the processing medium from organic solvents to water. By using aqueous solutions for the sol-gel reaction and film casting, the harmful effects of organic solvents are eliminated while the film preparation process remains simple and effective for industrial production.
3Ease of manufacture
If fluoropolymer films are obtained by reacting pre-gelled metal compound with functional fluoropolymer, then the composite is obtained as pellets, but the distribution of atomic elements in the film is not homogeneous
Solution Approach 1:
The electrolyte solution and other components are preliminarily mixed and incorporated into the hybrid composite during the sol-gel reaction process, before the material is formed into pellets or films. This preliminary uniform distribution ensures that atomic elements are homogeneously distributed throughout the final product, eliminating the heterogeneity problem.
Solution Approach 2:
The process inherently produces homogeneous composites by conducting the sol-gel reaction in a well-mixed aqueous solution where all components (metal alkoxide, fluoropolymer, electrolyte, water) are uniformly distributed before reaction. The resulting hybrid composite has homogeneous atomic distribution at the molecular level, which is maintained through to the final film or pellet form.
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 resulting polymer electrolyte membrane exhibits high conductivity and uniform atomic distribution, enabling efficient ion transport pathways without the need for solvent casting, thus enhancing industrial applicability.
Implementation Method 1
obtained by partially hydrolysing and/or polycondensing a metal compound
Implementation Method 2
partially hydrolysing and/or polycondensing a metal compound
Implementation Method 3
reacting in the molten state at least a fraction of hydroxyl groups of a functional fluoropolymer with at least a fraction of hydrolysable groups of the pre-gelled metal compound in the presence of an acid catalyst
Implementation Method 4
The resulting liquid mixture is then processed into a film by casting... having outstanding ionic conductivity
Data Source
AI summary
The invention pertains to a process for the manufacture of a polymer electrolyte based on a fluoropolymer hybrid organic/inorganic composite, to a polymer electrolyte obtained thereof and to uses of said polymer electrolyte and membranes obtained therefrom in various applications, especially in electrochemical and in photo-electrochemical applications.