Reinforced Separator Coating With Pre-Wetted Drum Phase Inversion
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Solution Overview
Problem
Existing methods for manufacturing thin reinforced separators for alkaline water electrolysis are complex and costly, with issues such as waviness and limited manufacturing speed due to the use of supporting casting drums or belts, which affect the mechanical qualities and ion conductivity of the separators.
Innovation Solution
A method involving a pre-wetted casting drum or engraved roller with a thin layer of non-solvent to facilitate rapid phase inversion and delamination of the dope solution, allowing for faster production of thin reinforced separators with improved mechanical properties and ion conductivity, without the need for larger drums or driven belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polymer solution is coated on both sides of a thin porous support, then the separator is reinforced, but waviness occurs and manufacturing complexity increases
Solution Approach 1:
The patent divides the coating process into two distinct stages: first coating the polymer solution on one side of the porous support, then coating the other side only after the first coating has set. This segmentation eliminates the waviness problem that occurs when coating both sides simultaneously on thin supports, while still achieving reinforcement.
Solution Approach 2:
The patent applies a preliminary coating on one side of the porous support before coating the other side. This preliminary action allows the first coating to establish adhesion and prevent waviness before the second coating is applied, simplifying the overall manufacturing process compared to simultaneous dual-sided coating.
2Ease of manufacture
If a temporary support is used to apply polymer solution on one side, then coating is simplified, but additional removal steps are required
Solution Approach 1:
The patent extracts the temporary support from the final product by designing a process where the polymer solution is coated directly on the porous support without requiring a temporary support. The porous support itself serves as the substrate for coating, eliminating the need for subsequent removal steps while maintaining coating simplicity.
3Reliability
If thin separators are used, then ion conductivity improves, but mechanical strength decreases
Solution Approach 1:
The patent creates a composite structure by coating polymer solution on the porous support, forming a multi-layer composite material. This composite structure provides both the thinness required for high ion conductivity and the additional polymer layer required for mechanical strength, resolving the trade-off between thickness and strength.
4Area of stationary object
If larger casting drums are used, then coating surface area increases, but manufacturing speed decreases
Solution Approach 1:
The patent employs a dynamic coating process where the porous support is fed through a coating apparatus with controlled coating zones. This dynamic approach allows efficient use of coating surface area without requiring large stationary drums, maintaining high manufacturing speed while ensuring proper coating application.
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 method enables less complex and cost-effective production of thin reinforced separators with enhanced mechanical qualities and ion conductivity, suitable for alkaline water electrolysis, by ensuring proper adhesion and penetration of the dope solution into the porous support, thereby improving manufacturing speed and efficiency.
Implementation Method 1
performing phase inversion of the applied polymer solution
Implementation Method 2
The applied polymer solution is then subjected to a liquid induced phase separation process
Implementation Method 3
The porous support is then impregnated with the applied polymer solution
Data Source
AI summary
A method of preparing a reinforced separator comprising the steps of:—providing a porous support (6) on a pre-wetted casting drum (23);—applying a dope solution (3) including a polymer resin and hydrophilic inorganic particles on a side of the porous support other than the side of the porous support in contact with the pre-wetted casting drum;—performing phase inversion (9, 1) of the applied polymer solution thereby obtaining a reinforced separator; and—removing the reinforced separator (7) from the casting drum; wherein the casting drum is pre-wetted with a non-solvent for the polymer resin.