Thermoplastic Membrane for Selective Cation Transfer
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Solution Overview
Problem
Existing electrolyte-separating membranes with ceramic supports face challenges in scaling up due to manufacturing difficulties, limiting the industrial application of selective cation transfer processes, despite achieving high Faradic yields and current densities.
Innovation Solution
A membrane with a porous thermoplastic synthetic support and a deposited active layer, where the support is manufactured using selective laser sintering and the active layer is applied by coating, allowing for large-scale production while maintaining high transfer performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic support is used in existing membranes, then high Faradic yields and current densities are achieved, but manufacturing difficulty increases and scaling up becomes problematic
Solution Approach 1:
The patent changes the material parameter of the support from ceramic to thermoplastic synthetic material, which fundamentally alters the manufacturing characteristics while maintaining the required functional properties for high Faradic yield in cation transfer applications
Solution Approach 2:
The patent creates a composite membrane structure combining thermoplastic synthetic support with active layer material, where the composite architecture enables both ease of manufacture at large scale and high electrochemical performance through the synergistic properties of the combined materials
2Productivity
If membrane thickness is reduced to increase transfer rate, then cation transfer efficiency improves, but mechanical strength decreases
Solution Approach 1:
The patent employs a thin active layer deposited on the thermoplastic support, creating a flexible film structure that achieves high transfer rates through the thin active layer while the underlying thermoplastic support provides the necessary mechanical strength and structural integrity
Solution Approach 2:
The composite structure combines a thin active layer with a thermoplastic synthetic support, where the thin film component enables high transfer rates and the bulk thermoplastic material provides mechanical strength, achieving both objectives simultaneously
3Power
If ceramic support is used, then high current densities are achieved, but device complexity increases due to manufacturing requirements
Solution Approach 1:
The patent changes the support material parameter from ceramic to thermoplastic synthetic material, which simplifies the manufacturing process and reduces device complexity while maintaining the capability to achieve high current densities through the active layer
Solution Approach 2:
The patent replaces the complex ceramic manufacturing system with a simpler thermoplastic processing system, substituting a complex mechanical/chemical manufacturing process with a more straightforward extrusion or molding process that reduces overall device complexity
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
Enables the production of membranes with large dimensions that retain high current densities and Faradic yields, facilitating industrial-scale selective cation transfer with improved mechanical and chemical resistance.
Implementation Method 1
the support is manufactured using selective laser sintering
Implementation Method 2
the active layer is applied by coating
Implementation Method 3
the active layer being deposited on the supporting and leak-proof layer, characterized in that the support is in a thermoplastic synthetic material
Implementation Method 4
transfer of the cations through the membrane is ensured by generating a potential difference between either one anode in the first electrolyte and a cathode in the second electrolyte, or between an anode in the first electrolyte and the transfer membrane, so as to cause insertion of the cations into the active layer of the transfer membrane on the side of the first electrolyte, diffusion of the cations into the active layer, and then their de-insertion in the second electrolyte
Implementation Method 5
the support is pervious and allows an electrolyte contained on the side of the support to attain the active layer
Data Source
AI summary
An electrolyte-separating membrane includes a carrier made of a porous and permeable synthetic thermoplastic material that is larger than 0.8 mm in thickness and an active layer made of a material able to induce insertion and deinsertion reactions for selective transfer of cations through the membrane. The active layer is deposited on the carrier and is hermetic. The material of the active layer may in particular be a molybdenum cluster chalcogenide. The invention aims to provide an electrolyte-separating membrane that is able to transfer cations selectively and that may be manufactured with large dimensions. The invention also relates to a cation transfer method employing this membrane and to a process for manufacturing said membrane, in particular by selective laser sintering of a powdered polymer.