Ion Exchange Membranes via Curable Composite Composition
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Solution Overview
Problem
The production of ion exchange membranes faces challenges in achieving thin membranes with minimal defects, good permselectivity, low electrical resistance, strength, flexibility, and resistance to chemicals, while also requiring cost-effective and scalable production processes.
Innovation Solution
A curable composition comprising 2.5 to 50 wt% crosslinker with two acrylamide groups, 20 to 65 wt% curable ionic compound, 15 to 45 wt% solvent, and 0 to 10 wt% free radical initiator, with a molar ratio of crosslinker to curable ionic compound between 0.1 to 1.5, is used to prepare membranes with specific pH ranges, which are then cured to form membranes with desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin membranes are produced, then permselectivity and electrical resistance improve, but mechanical strength and flexibility deteriorate
Solution Approach 1:
The patent uses composite materials by combining ion exchange resin particles with a polymer matrix material to form a membrane. This composite structure provides both the ion exchange functionality for permselectivity and the polymer matrix for mechanical strength, resolving the contradiction between thin membrane production and mechanical strength maintenance.
Solution Approach 2:
The membrane is designed with a porous structure containing ion exchange resin particles distributed within the polymer matrix. This porous architecture enables ion transport for good permselectivity while the polymer matrix provides structural integrity and flexibility, allowing thin membranes to maintain mechanical strength.
2Manufacturing precision
If membrane thickness is reduced, then electrical resistance decreases, but production complexity and defect risk increase
Solution Approach 1:
The patent combines multiple functions into a single membrane structure: the polymer matrix provides structural support, the ion exchange resin particles provide ion selectivity, and the porous structure enables transport. This integration simplifies production by creating a multifunctional material that achieves good permselectivity and low resistance in thin configurations without requiring complex multi-layer assemblies.
Solution Approach 2:
The patent controls the physical and chemical parameters of the membrane formation process, including the concentration and size distribution of ion exchange resin particles, the polymer matrix composition, and the porosity. By optimizing these parameters, the patent achieves uniform thin membranes with minimal defects and good electrical properties, reducing production complexity.
3Ease of operation
If membrane flexibility is increased for winding applications, then mechanical integrity over time deteriorates
Solution Approach 1:
The patent applies local quality by creating a heterogeneous structure where ion exchange resin particles are distributed within the polymer matrix. The polymer matrix provides flexibility for winding applications, while the dispersed resin particles and crosslinked structure provide local reinforcement that maintains physical integrity over time, resolving the contradiction between flexibility and long-term reliability.
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 membranes exhibit a good balance of permselectivity and low electrical resistance, are strong and flexible, resistant to chemicals, and can be produced cost-effectively in large quantities using a rapid and continuous process.
Implementation Method 1
0 to 10 wt% of free radical initiator
Implementation Method 2
20 to 65 wt% curable ionic compound comprising an ethylenically unsaturated group and an anionic group
Data Source
AI summary
A curable composition comprising:(i) 2.5 to 50 wt % crosslinker comprising at least two acrylamide groups;(ii) 20 to 65 wt % curable ionic compound comprising an ethylenically unsaturated group and an anionic group;(iii) 15 to 45 wt % solvent; and(iv) 0 to 10 wt % of free radical initiator;wherein the molar ratio of (i):(ii) is 0.1 to 1.5.The compositions are useful for preparing ion exchange membranes.