Polyphenylene Sulfide Separator with Barium Sulfate for Alkaline Electrolysis
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Solution Overview
Problem
Current separators in alkaline water electrolyzers face challenges such as toxicity, limited efficiency, and high energy consumption due to instability at elevated temperatures, and the need for materials that offer good gas separation, ionic conductivity, and mechanical stability while being cost-effective and environmentally friendly.
Innovation Solution
A woven or nonwoven web comprising fibers made from specific polymers like polyphenylene sulfide with inorganic salts such as barium sulfate deposited on their surface, enhancing mechanical and chemical stability while improving ionic conductivity and gas tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If asbestos based separators are used, then mechanical stability and ionic conductivity are improved, but toxicity and environmental harm increase
Solution Approach 1:
The patent removes asbestos from the separator composition entirely and replaces it with alternative materials such as polyphenylene sulfide (PPS) combined with inorganic fillers like barium sulfate, aluminum oxide, or silicon oxide. This extraction eliminates the toxic component while maintaining the separator's structural integrity and ionic conductivity through the synergistic combination of polymer matrix and inorganic additives.
Solution Approach 2:
The patent employs composite material structures consisting of polymer matrices (e.g., polyphenylene sulfide) reinforced with inorganic fillers (barium sulfate, aluminum oxide, silicon oxide). These composites provide both mechanical strength and chemical stability without the toxicity associated with asbestos, achieving the desired reliability through material composition rather than hazardous substances.
2Temperature
If nickel oxide separators are used, then stability at elevated temperatures is improved, but cost effectiveness and lifetime are worsened
Solution Approach 1:
The patent modifies the chemical composition parameters by replacing nickel oxide with polymer-inorganic composite materials that exhibit comparable or superior thermal stability. The polyphenylene sulfide matrix combined with inorganic fillers maintains structural integrity at elevated temperatures while significantly reducing manufacturing costs and extending operational lifetime compared to nickel oxide separators.
3Object-affected harmful factors
If Zirfon Perl membranes are used, then gas separation is improved, but ionic conductivity and thickness suitability are worsened
Solution Approach 1:
The patent applies local quality enhancement by incorporating inorganic fillers specifically at the pore structures and surfaces of the polyphenylene sulfide matrix. This localized reinforcement improves gas separation performance in critical areas while maintaining overall ionic conductivity through the continuous polymer phase, achieving both properties without compromising either function.
4Strength
If separator thickness is increased, then mechanical stability is improved, but ionic conductivity and energy consumption are worsened
Solution Approach 1:
The patent uses composite materials with inorganic fillers dispersed in the polymer matrix to enhance mechanical strength and stiffness. This allows the separator to maintain adequate mechanical stability at reduced thickness levels, thereby minimizing ionic transport resistance and energy consumption while still providing sufficient structural support.
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 solution provides a separator with improved ionic conductivity and gas tightness, reducing energy consumption and extending operational life, while being non-toxic and cost-effective, thus addressing the limitations of existing materials.
Implementation Method 1
one or more inorganic salts selected from the group consisting of barium sulfate, strontium sulfate, calcium sulfate, lead(II) sulfate or mixtures thereof; wherein the one or more inorganic salts are present on the surface of at least part of the fibers
Data Source
AI summary
The present invention relates to a woven or nonwoven web comprising:fibers comprising one or more polymers selected from the group consisting of polyarylene sulfides, polyolefins, polyamide imides, polysulfones, polyethersulfones, polyetherketones, polyether etherketones or copolymers thereof; andone or more inorganic salts selected from the group consisting of barium sulfate, strontium sulfate, calcium sulfate, lead(II) sulfate or mixtures thereof;wherein the one or more inorganic salts are present on the surface of at least part of the fibers.The woven or nonwoven web is particularly suitable for use in alkaline water electrolysis.