Compositions comprising poly(arylene ether sulfones)

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Solution Overview

Problem

Existing polymer materials used in bipolar plates for fuel cells suffer from insufficient toughness, temperature resistance, and mechanical performance, limiting their applicability and durability.

Innovation Solution

A composition comprising 15 to 90% polyarylene(ether)sulfone with a Viscosity Number less than 42 ml/g, combined with 5 to 80% graphite, 5 to 80% conductive carbon black, and optional carbon nanotubes and additives, optimized for mechanical and electrical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PPS (polyphenylenesulfide) is used as matrix for highly conductive compounds, then electrical conductivity is improved, but toughness deteriorates leading to plate fracture

Engineering Contradiction:

Improveelectrical conductivityVSAvoidtoughness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the polymer matrix from PPS to polyarylene(ether)sulfone with specifically controlled viscosity (Vn < 42 ml/g), which fundamentally alters the material parameters to achieve both high conductivity and improved toughness, resolving the contradiction between electrical performance and mechanical strength

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite material system combining polyarylene(ether)sulfone matrix with multiple carbon-based conductive additives (graphite, carbon black, carbon nanotubes) in optimized ratios, achieving synergistic effects that simultaneously improve electrical conductivity and mechanical toughness

Inventive Principle:

Principle #40Composite materials

2Reliability

If high quantities of carbon-based conductive additives are used, then electrical conductivity is improved, but toughness deteriorates

Engineering Contradiction:

Improveelectrical conductivityVSAvoidtoughness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent optimizes the quantity and distribution parameters of carbon-based additives, using specific weight ratios (5-80% graphite, 5-80% carbon black, 0-25% carbon nanotubes) combined with low-viscosity matrix to achieve percolation threshold for conductivity while maintaining structural integrity and toughness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a multi-component composite strategy using different types of carbon additives (graphite for structure, carbon black for conductivity network, carbon nanotubes for reinforcement) that work synergistically to achieve both high electrical conductivity and maintained toughness

Inventive Principle:

Principle #40Composite materials

3Temperature

If polymers with higher modulus are used for elevated temperatures, then temperature resistance is improved, but processability deteriorates

Engineering Contradiction:

Improvetemperature resistanceVSAvoidprocessability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent selects polyarylene(ether)sulfone with specifically controlled viscosity number (Vn < 42 ml/g) that maintains appropriate melt flow characteristics for processing while providing high-temperature service performance, resolving the contradiction between processability and temperature resistance through precise parameter control

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250206912A1Compositions comprising poly(arylene ether sulfones)

Publication Date: 2025.06.26 BASF SE

AI summary

The present invention relates to compositions comprising polyarylene(ether)sulfones having high electrical conductivity, good chemical resistance and improved processability suitable to be used in the production of bipolar plates for fuel cells or electrolysis units.