Pore-Filled Ion Exchange Membrane With Removed Surface Resin
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Solution Overview
Problem
Conventional ion exchange membranes face issues with mechanical strength, durability, and ion exchange capacity due to compatibility problems between the support and the ion exchange resin layer, leading to peeling and separation, and difficulties in adjusting membrane properties such as thickness, electrical conductivity, and pore diameter.
Innovation Solution
A pore-filled ion exchange polyelectrolyte composite membrane is manufactured through a roll-to-roll process by preparing an ion exchange precursor solution, impregnating a porous polymer support, compressing it with films, crosslinking using UV rays, and detaching the support to expose the porous structure, resulting in a membrane with improved mechanical strength and ion exchange capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a separate support is used to improve mechanical properties, then mechanical strength is improved, but compatibility problems occur between the support and ion exchange resin layer leading to peeling and separation
Solution Approach 1:
The patent merges the support structure and ion exchange resin layer into a single integrated membrane by removing the separate support. The porous substrate is completely replaced with a self-supported ion exchange membrane structure, eliminating the interface between support and resin layer that caused peeling and separation issues.
Solution Approach 2:
The patent uses a composite structure consisting of a porous substrate impregnated with ion exchange resin, creating a unified material system. The porous substrate serves as both the structural framework and the ion exchange medium, combining mechanical support and ion exchange functionality in one composite material.
2Ease of manufacture
If conventional manufacturing processes are used, then production is simple, but it is very difficult to change configuration and control factors such as thickness, electrical conductivity, and mechanical strength
Solution Approach 1:
The patent enables control of membrane properties by adjusting parameters in the ion exchange precursor solution formulation and impregnation process. By changing the concentration, composition, and processing conditions of the precursor solution, the patent can control thickness, electrical conductivity, and mechanical strength of the final membrane.
Solution Approach 2:
The patent prepares an ion exchange precursor solution in advance with specific composition and concentration, then impregnates the porous substrate with this pre-formulated solution. This preliminary preparation allows precise control over the final membrane properties while maintaining a simple manufacturing process.
3Loss of energy
If ion exchange membranes are made thinner to reduce resistance, then electrical conductivity is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent uses a porous substrate structure that provides high surface area and three-dimensional ion exchange pathways. The porous structure allows the membrane to be thin for low resistance while the interconnected pore network and substrate framework maintain mechanical strength. The porosity enables efficient ion transport without requiring thick membranes.
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 process yields a membrane with low film resistance, reduced swelling, and lower thickness, enabling versatile applications while simplifying the manufacturing process and reducing costs.
Implementation Method 1
impregnating a porous polymer support with the ion exchange precursor solution
Implementation Method 2
crosslinking the ion exchange precursor solution by irradiating ultraviolet rays
Implementation Method 3
compressing it with films
Data Source
AI summary
A pore-filled ion exchange polyelectrolyte composite membrane from which the surface ion exchange polyelectrolyte has been removed and a method of manufacturing the same are provided. The ion exchange polyelectrolyte composite membrane exhibits low film resistance and low in-plane-direction swelling degree, and has a smaller film-thickness than a commercial film, and thus, can be used for various purposes. In addition, since the pore-filled ion exchange polyelectrolyte composite membrane is continuously manufactured through a roll-to-roll process, the manufacturing process is simple, and manufacturing costs can be greatly reduced.