Porous Ion-Exchange Separator for Moisture-Stable Cell Assembly

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Solution Overview

Problem

Anion exchange membranes used in electrochemical conversion cells are prone to drying and deformation at room temperature, leading to reduced mechanical properties and processability during assembly.

Innovation Solution

A separator structure is developed with a hydrophilic or hydrophobic porous structure layer stacked on an ion exchange membrane to maintain moisture and improve mechanical properties, comprising a base membrane with a hydrophilic porous structure layer made of PTFE or hydrophobic layers like PVDF, without the need for binders.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If an anion exchange membrane is used as the ion-selective separator to achieve excellent carbon dioxide conversion rate, then the electrochemical conversion performance is improved, but the membrane is easily dried and deformed at room temperature, leading to reduced mechanical properties and processability

Engineering Contradiction:

Improvecarbon dioxide conversion rateVSAvoidmechanical properties at room temperature

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies composite materials by combining the anion exchange membrane with a porous structure layer to create a separator with both high ion conductivity for CO2 conversion and improved mechanical strength. The porous layer acts as a structural reinforcement that prevents drying and deformation while maintaining the membrane's electrochemical performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes porous materials by incorporating a porous structure layer with controlled porosity. This porous layer provides mechanical strength and structural stability to the membrane, preventing it from drying out and deforming at room temperature, while still allowing ion transport necessary for high CO2 conversion rates.

Inventive Principle:

Principle #31Porous materials

2Reliability

If the anion exchange membrane is stored in a setting with sufficient moisture to prevent drying, then the membrane integrity is maintained, but the membrane dries out quickly when exposed at room temperature during assembly, causing breakage or damage

Engineering Contradiction:

Improvemembrane integrityVSAvoidmoisture retention time at room temperature

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The porous structure layer serves as a moisture reservoir that slowly releases water to the anion exchange membrane, extending the membrane's moisture retention time during room temperature assembly operations. This gradual moisture release prevents the membrane from drying out and becoming brittle during handling.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent applies beforehand cushioning by incorporating the porous structure layer that pre-stores moisture to cushion against the drying effect during assembly. This protective layer ensures the membrane remains hydrated and mechanically robust throughout the assembly process, preventing breakage or damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If a porous structure layer is stacked on the ion exchange membrane to maintain moisture and improve mechanical properties, then the processability is improved, but the structure complexity increases

Engineering Contradiction:

Improveprocessability during assemblyVSAvoidseparator structure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the separator into two distinct functional layers: the anion exchange membrane layer for ion transport and the porous structure layer for mechanical support and moisture retention. This segmentation allows each layer to be optimized independently and simplifies the manufacturing process by enabling separate production and assembly of the layers.

Inventive Principle:

Principle #1Segmentation

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 separator maintains moisture wettability at room temperature, enhancing mechanical properties and processability while maintaining or improving carbon monoxide Faraday efficiency and carbon dioxide conversion rates.

Implementation Method 1

a porous structure layer having hydrophilic or hydrophobic properties is stacked on a surface of an ion exchange membrane, which in turn constantly retains a certain amount of moisture

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

the hydrophilic porous structure layer includes a hydrophilic polymer

Methodology Applied

Scientific EffectHydrophilic absorption: Absorption (physical)

Data Source

PatentUS20260014527A1Separator and Electrochemical Conversion Cell Including the Same

Publication Date: 2026.01.15 LG CHEM LTD

AI summary

A separator includes a base membrane and a hydrophilic porous structure layer or a hydrophobic porous structure layer. The hydrophilic porous structure layer or the hydrophobic porous structure layer is stacked on at least one side of the base membrane. The base membrane is an anion exchange membrane, a cation exchange membrane, or an amphoteric ion exchange membrane.