U.S. patent application number 13/066225 was filed with the patent office on 2011-10-27 for solid polymer electrolyte composite membrane comprising porous ceramic support.
Invention is credited to Anthony B. LaConti, Cortney K. Mittelsteadt.
Application Number | 20110262693 13/066225 |
Document ID | / |
Family ID | 36816020 |
Filed Date | 2011-10-27 |
United States Patent
Application |
20110262693 |
Kind Code |
A1 |
Mittelsteadt; Cortney K. ;
et al. |
October 27, 2011 |
Solid polymer electrolyte composite membrane comprising porous
ceramic support
Abstract
A solid polymer electrolyte composite membrane and method of
manufacturing the same. The composite membrane comprises a porous
ceramic support having a top surface and a bottom surface. The
porous ceramic support may be formed by laser micromachining a
ceramic sheet or may be formed by electrochemically oxidizing a
sheet of the base metal. A solid polymer electrolyte fills the
pores of the ceramic support and preferably also covers the top and
bottom surfaces of the support. Application of the solid polymer
electrolyte to the porous support may take place by applying a
dispersion to the support followed by a drying off of the solvent,
by hot extrusion of the solid polymer electrolyte (or by hot
extrusion of a precursor of the solid polymer electrolyte followed
by in-situ conversion of the precursor to the solid polymer
electrolyte) or by in-situ polymerization of a corresponding
monomer of the solid polymer electrolyte.
Inventors: |
Mittelsteadt; Cortney K.;
(Wayland, MA) ; LaConti; Anthony B.; (Lynnfield,
MA) |
Family ID: |
36816020 |
Appl. No.: |
13/066225 |
Filed: |
April 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11239647 |
Sep 29, 2005 |
7947405 |
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13066225 |
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60614143 |
Sep 29, 2004 |
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Current U.S.
Class: |
428/117 ;
252/62.2; 427/554; 428/305.5; 521/33 |
Current CPC
Class: |
H01M 8/1083 20130101;
H01M 8/1081 20130101; H01G 11/56 20130101; H01M 8/1023 20130101;
Y02E 60/50 20130101; Y02P 70/50 20151101; H01G 9/025 20130101; H01M
8/1088 20130101; H01M 2300/0082 20130101; Y10T 428/249954 20150401;
C25B 13/08 20130101; H01G 9/038 20130101; C08J 5/2218 20130101;
Y10T 428/24157 20150115; H01G 9/02 20130101; H01M 8/1067 20130101;
G01N 27/4071 20130101; H01M 8/106 20130101; H01M 2300/0094
20130101; Y02E 60/13 20130101; B01D 69/10 20130101; H01M 8/1039
20130101 |
Class at
Publication: |
428/117 ;
252/62.2; 521/33; 428/305.5; 427/554 |
International
Class: |
B32B 3/12 20060101
B32B003/12; B05D 3/06 20060101 B05D003/06; B32B 3/26 20060101
B32B003/26; H01G 9/025 20060101 H01G009/025; C08F 8/38 20060101
C08F008/38 |
Claims
1. A solid polymer electrolyte composite membrane, said solid
polymer electrolyte composite membrane comprising: (a) a ceramic
support, said ceramic support having opposing top and bottom
surfaces and a plurality of pores extending from said top surface
to said bottom surface, wherein at least some of said pores are
positioned in a peripheral portion of the ceramic support and at
least some of said pores are positioned in a non-peripheral portion
of the ceramic support and wherein said pores are positioned in a
greater concentration in said non-peripheral portion than in said
peripheral portion; and (b) a first solid polymer electrolyte at
least partially filling at least some of said pores.
2. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein each of said plurality of pores extends in a
straight line perpendicularly from said top surface to said bottom
surface.
3. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said plurality of pores are arranged in a
non-random pattern.
4. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein at least some of said pores are arranged in a
honeycomb pattern.
5. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said pores are cylindrical in shape.
6. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said pores have a diameter of about 0.01 to 200
microns.
7. The solid polymer electrolyte composite membrane as claimed in
claim 6 wherein said pores have a diameter of about 1 to 200
microns.
8. The solid polymer electrolyte composite membrane as claimed in
claim 6 wherein said pores have a diameter of about 0.01 to 100
microns.
9. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said pores constitute about 20% to 95% of said
ceramic support.
10. The solid polymer electrolyte composite membrane as claimed in
claim 9 wherein said pores constitute about 40% to 70% of said
ceramic support.
11. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said ceramic support comprises a material selected
from the group consisting of silica, quartz, glass, boron
carbonate, silicon carbide, alumina, titania, silica tungstate,
sintered valve metal oxides and non-conductive diamond or
diamond-like coatings.
12. The solid polymer electrolyte composite membrane as claimed in
claim 11 wherein said ceramic support comprises a ceramic selected
from the group consisting of silica, alumina and silicon
carbide.
13. The solid polymer electrolyte composite membrane as claimed in
claim 12 wherein said ceramic support is made of alumina.
14. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said ceramic support has a thickness of about 1 to
50 microns.
15. The solid polymer electrolyte composite membrane as claimed in
claim 14 wherein said ceramic support has a thickness of about 7.5
to 15 microns.
16. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said first solid polymer electrolyte is selected
from the group consisting of polymer compositions that contain
metal salts, polymeric gels that contain electrolyte and ion
exchange resins.
17. The solid polymer electrolyte composite membrane as claimed in
claim 16 wherein said first solid polymer electrolyte is an ion
exchange resin.
18. The solid polymer electrolyte composite membrane as claimed in
claim 17 wherein said first solid polymer electrolyte is
perfluorosulfonic acid (PFSA) polymer.
19. The solid polymer electrolyte composite membrane as claimed in
claim 18 wherein said PFSA polymer has an equivalent weight of
about 200 to 2000.
20. The solid polymer electrolyte composite membrane as claimed in
claim 19 wherein said PFSA polymer has an equivalent weight of
about 500 to 1200.
21. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein all of said pores are completely filled with said
first solid polymer electrolyte and wherein said top and bottom
surfaces of said ceramic support are covered with said first solid
polymer electrolyte.
22. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said solid polymer electrolyte composite membrane
has a thickness of about 5 to 300 microns.
23. The solid polymer electrolyte composite membrane as claimed in
claim 22 wherein said solid polymer electrolyte composite membrane
has a thickness of about 7.5 to 200 microns.
24. The solid polymer electrolyte composite membrane as claimed in
claim 1 wherein said solid polymer electrolyte composite membrane
has an ionic conductivity of 0.001 S/cm to 0.7 S/cm at room
temperature with a relative humidity of 100%.
25. A method of preparing a solid polymer electrolyte composite
membrane, said method comprising the steps of: (a) providing a
ceramic support, said ceramic support having a top surface and a
bottom surface; (b) lasing at least one pore in said ceramic
support, said at least one pore extending transversely from said
top surface to said bottom surface; and (c) filling at least one of
said at least one pore with a first solid polymer electrolyte.
26. The method as claimed in claim 25 wherein said step of
providing a ceramic support comprises providing a metal sheet and
electrochemically oxidizing said metal sheet.
27. A method of preparing a perfluorosulfonic acid polymer, said
method comprising the steps of: (a) providing a sulfonyl fluoride
precursor of said perfluorosulfonic acid polymer; and (b) adding a
weak base to said sulfonyl fluoride precursor to convert said
sulfonyl fluoride precursor to said perfluorosulfonic acid polymer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 11/239,647, filed Sep. 29, 2005, which, in
turn, claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional
Patent Application Ser. No. 60/614,143, filed Sep. 29, 2004, both
of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to solid polymer
electrolyte membranes of the type suitable for use in
electrochemical devices and relates more particularly to a novel
such membrane.
[0003] Electrochemical devices of the type comprising a solid
polymer electrolyte membrane (PEM) sandwiched between a pair of
electrodes are well-known, such electrochemical devices finding
applications as, for example, fuel cells, electrolyzers, sensors,
gas concentrators, gas compressors, supercapacitors,
ultracapacitors and industrial electrochemical process units.
[0004] A common type of solid polymer electrolyte membrane consists
of a homogeneous perfluorosulfonic acid (PFSA) polymer, said PFSA
polymer being formed by the copolymerization of tetrafluoroethylene
and perfluorovinylether sulfonic acid. See e.g., U.S. Pat. No.
3,282,875, inventors Connolly et al., issued Nov. 1, 1966; U.S.
Pat. No. 4,470,889, inventors Ezzell et al., issued Sep. 11, 1984;
U.S. Pat. No. 4,478,695, inventors Ezzell et al., issued Oct. 23,
1984; U.S. Pat. No. 6,492,431, inventor Cisar, issued Dec. 10,
2002, all of which are incorporated herein by reference. A
commercial embodiment of a perfluorosulfonic acid polymer PEM is
available from DuPont (Wilmington, Del.) as NAFION.RTM. PFSA
polymer.
[0005] Although PFSA PEMs function in a generally satisfactory
manner in electrochemical devices, there nonetheless remains room
for improvement in certain properties of PFSA PEMs. For example,
one common difficulty associated with PFSA PEMs is a lack of
mechanical strength, resulting in a tendency for the PFSA PEMs to
tear, especially when being handled (such as during assembly of an
electrochemical cell) or in stressed areas where compression is
applied thereto (such as in peripheral areas of PEMs sealed under
pressure to other electrochemical cell components). Such a lack of
mechanical strength also often leads to electrical shorting, which
results in premature failures during cell operation as the typical
porous electrodes in contact with the PEM have a tendency to
penetrate the softened PEM. This problem of shorting is even
greater when the membrane is made thin (e.g., less than 25 microns)
in order to decrease membrane resistance.
[0006] Because the tendency to tear and to short is greatest when
the PFSA PEMs are wet (especially at elevated temperatures) and
because the PFSA PEMs must be wet in order to function properly,
one approach to this problem has been to assemble electrochemical
cells with dry PEMs and then to subject the PEMs to a
humidification process. This approach, however, has its own
shortcomings. One such shortcoming is that the dry assembly
requires special moisture-free facilities, such as a "dry room."
Another such shortcoming is that the humidification process is
time-consuming. Still another such shortcoming is that the
humidification process typically results in the PEM swelling in a
non-uniform manner, thereby creating stress in some areas of the
PEM, as well as in other components of the cell that are in contact
with the PEM, and introducing irregularities in the contact
pressure applied over the entire active surface area of the PEM.
(When the contact pressure is not uniform over the entire active
surface area of the PEM, the performance of the electrochemical
cell is adversely affected.) As can readily be appreciated, such
irregularities are amplified where humidification is applied to a
plurality of PEM-containing fuel cells arranged in a stack.
[0007] Moreover, if the PEM is subjected to variable conditions of
humidity (e.g., alternating wet and dry intervals during periods of
use and non-use, respectively), the membrane will undergo
additional dimensional changes as it swells when wet and shrinks
when dry. Such dimensional changes cause further stress to the PEM
and to the other cell components, all of which are tightly packed
together. If sufficiently great, such stress results in damage to
the PEM and/or to the cell components in contact therewith.
Pinholes/microcracks have a tendency to form along the cell or
flow-field edges where one side of the membrane is heavily
compressed by the fixture while the other side can still partially
swell.
[0008] One approach that has been taken to address the
aforementioned problem of low mechanical strength of PFSA PEMs has
been to cross-link the membrane polymer. Such cross-linking reduces
the swelling of the membrane when wet which, in turn, reduces the
deterioration of the mechanical strength of the membrane when wet.
Unfortunately, however, such cross-linking tends to make the
membrane undesirably brittle under dry conditions.
[0009] Another approach to this problem is disclosed in U.S. Pat.
No. 6,635,384, inventors Bahar et al., which issued Oct. 21, 2003,
and which is incorporated herein by reference. In the
aforementioned '384 patent, there is described a composite membrane
that comprises a microporous sheet, said microporous sheet
preferably being an expanded polytetrafluoroethylene (ePTFE)
membrane, said ePTFE membrane preferably being formed by stretching
a sheet of polytetrafluoroethylene (PTFE) until pores are formed
therein. The structure defining the pores of the microporous sheet
is then at least partially covered with a functional material
selected from (i) inorganic particulate; (ii) metal; and (iii) an
organic polymer. In addition, the pores of the sheet are then at
least partially filled with polymer electrolyte selected from (i)
polymer compositions that contain metal salts; (ii) polymeric gels
that contain electrolyte; and (iii) ion exchange resins, such as
PFSA.
[0010] One disadvantage that has been noted by the present
inventors regarding the foregoing composite membrane is that the
pores of the expanded polytetrafluoroethylene (ePTFE) sheet tend to
follow a tortuous pathway between opposing surfaces of the ePTFE
sheet, as opposed to following a direct or straight pathway between
opposing surfaces. As a result of these tortuous pathway's, protons
conducted through the pores (by means of the polymer electrolyte
that is disposed within the pores) have to travel considerably
longer pathways through the membrane than merely the thickness of
the membrane. Such longer pathways result in a reduction in the
conductivity of the membrane and an increase in the resistivity of
the membrane.
[0011] Another disadvantage that has been noted by the present
inventors regarding the foregoing composite membrane is that a
microporous sheet of ePTFE possesses only slightly better
mechanical strength than a PFSA PEM. Consequently, the foregoing
composite membrane is not significantly stronger than a PFSA PEM
and is subject to the same types of shortcomings discussed above in
connection with PFSA PEMs.
[0012] Still another disadvantage that has been noted by the
present inventors regarding the foregoing composite membrane is
that the stretching process that is used to expand the PTFE sheet
to create the desired pores tends to result in a fairly uniform yet
random distribution of pores throughout the sheet and cannot be
tailored to control the positioning or concentration of pores in
particular regions of the sheet. This is unfortunate because
certain regions of the membrane, such as the membrane active area
edges/corners or the membrane contact area with the current
collector, are typically subjected to greater stresses than other
regions. Consequently, pores in these regions of high stress
undesirably diminish membrane strength in those regions where
membrane strength is needed most.
SUMMARY OF THE INVENTION
[0013] It is an object of the present invention to provide a novel
solid polymer electrolyte membrane of the type that is suitable for
use in electrochemical devices, such as, but not limited to, fuel
cells, electrolyzers, sensors, gas concentrators, gas compressors,
supercapacitors, ultracapacitors and industrial electrochemical
process units.
[0014] It is another object of the present invention to provide a
solid polymer electrolyte membrane of the type described above that
overcomes at least some of the drawbacks discussed above in
connection with existing solid polymer electrolyte membranes.
[0015] Therefore, according to one aspect of the invention, there
is provided a solid polymer electrolyte composite membrane, said
solid polymer electrolyte composite membrane comprising (a) a
ceramic support, said ceramic support having opposing top and
bottom surfaces and a plurality of pores extending from said top
surface to said bottom surface; and (b) a first solid polymer
electrolyte at least partially filling at least some of said
pores.
[0016] In a preferred embodiment, the ceramic support contains or
is made of at least one of silica, quartz, glass, boron carbonate,
silicon carbide, alumina, titania, silica tungstate, sintered valve
metal oxides (e.g., tantalum or niobium oxide) and non-conductive
diamond or diamond-like coatings, the support having a thickness of
about 1 .mu.m to 50 .mu.m. A plurality of cylindrical pores are
formed in the support by laser micromachining. The pores have a
diameter of about 1 .mu.m to 200 .mu.m and are arranged in a
defined pattern, such as in a uniform hexangular pattern or in a
pattern in which fewer pores are located in areas of higher
membrane stress and more pores are located in areas of lower
membrane stress. A solid polymer electrolyte, such as PFSA polymer,
fills the pores. This may be effected, for example, by filling the
pores with a solution/dispersion of the solid polymer electrolyte
and then drying off the solvent, by filling the pores with a
precursor of the solid polymer electrolyte and then converting said
precursor to said solid polymer electrolyte by base hydrolysis, or
by filling the pores with a monomer of the solid polymer
electrolyte and then polymerizing the monomer in-situ. Additional
solid polymer electrolyte, which may be the same as or different
than that filling the pores, may be applied to one or both of the
top and bottom surfaces of the ceramic support.
[0017] In another preferred embodiment, a porous ceramic support is
prepared by the controlled electrochemical oxidation of a sheet of
the base metal. The pores of such a support may have a diameter of
about 0.01 micron to 100 microns and may be arranged in a honeycomb
pattern. Where the pores have a diameter less than about 0.1
micron, the pores are preferably not filled using a
solution/dispersion of the solid polymer electrolyte, but rather,
are preferably filled using the techniques identified above
involving base hydrolysis of a precursor or by in-situ
polymerization.
[0018] The present invention is also directed at methods of
preparing a solid polymer electrolyte composite membrane. According
to one aspect, said method comprises the steps of (a) providing a
ceramic support, said ceramic support having a top surface and a
bottom surface; (b) lasing at least one pore in said ceramic
support, said at least one pore extending transversely from said
top surface to said bottom surface; and (c) filling at least one of
said at least one pore with a first solid polymer electrolyte.
[0019] According to another aspect, said method comprises the steps
of (a) providing a metal sheet; (b) electrochemically oxidizing
said metal sheet to form a ceramic support having a top surface and
a bottom surface, said ceramic support having at least one pore
extending transversely from said top surface to said bottom
surface; and (c) filling at least one of said at least one pore
with a first solid polymer electrolyte.
[0020] The present invention is further directed at a method of
preparing a perfluorosulfonic acid polymer, said method comprising
the steps of (a) providing a sulfonyl fluoride precursor of said
perfluorosulfonic acid polymer; and (b) adding a weak base to said
sulfonyl fluoride precursor to convert said sulfonyl fluoride
precursor to said perfluorosulfonic acid polymer.
[0021] The present invention is also directed to membrane electrode
assemblies incorporating the above-described composite composite
membranes and to electrochemical devices incorporating the
above-described composite membranes, such electrochemical devices
including, but not being limited to, fuel cells, electrolyzers, gas
concentrators, gas compressors, sensors, supercapacitors,
ultracapacitors, and industrial electrochemical process units.
[0022] For purposes of the present specification and claims, it is
to be understood that certain relational terms used herein, such as
"above," "below," "top," "bottom," "over," "under," "in front of,"
or "behind," when used to denote the relative positions of two or
more components of an electrochemical device are used to denote
such relative positions in a particular orientation and that, in a
different orientation, the relationship of said components may be
reversed or otherwise altered.
[0023] Additional objects, as well as features and advantages, of
the present invention will be set forth in part in the description
which follows, and in part will be obvious from the description or
may be learned by practice of the invention. In the description,
reference is made to the accompanying drawings which form a part
thereof and in which is shown by way of illustration various
embodiments for practicing the invention. The embodiments will be
described in sufficient detail to enable those skilled in the art
to practice the invention, and it is to be understood that other
embodiments may be utilized and that structural changes may be made
without departing from the scope of the invention. The following
detailed description is, therefore, not to be taken in a limiting
sense, and the scope of the present invention is best defined by
the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are hereby incorporated
into and constitute a part of this specification, illustrate
various embodiments of the invention and, together with the
description, serve to explain the principles of the invention. In
the drawings wherein like reference numerals represent like
parts:
[0025] FIG. 1 is a schematic section view of a first embodiment of
a solid polymer electrolyte composite membrane constructed
according to the teachings of the present invention;
[0026] FIGS. 2(a) and 2(b) are top and perspective views,
respectively, of the non-electrically-conductive support shown in
FIG. 1;
[0027] FIG. 3 is a fragmentary top view of a
non-electrically-conductive support that may be used as an
alternative to the non-electrically-conductive support of FIGS.
2(a) and 2(b);
[0028] FIG. 4 is a schematic depiction of the laser micromachining
technique of near-field imaging;
[0029] FIG. 5 is a schematic section view of a second embodiment of
a solid polymer electrolyte composite membrane constructed
according to the teachings of the present invention;
[0030] FIG. 6 is a schematic section view of a third embodiment of
a solid polymer electrolyte composite membrane constructed
according to the teachings of the present invention; and
[0031] FIG. 7 is an image, taken from the top, of the
non-electrically-conductive support of FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] Referring now to FIG. 1, there is shown a schematic section
view of a first embodiment of a solid polymer electrolyte composite
membrane constructed according to the teachings of the present
invention, said solid polymer electrolyte composite membrane being
represented generally by reference numeral 11.
[0033] Composite membrane 11 comprises a
non-electrically-conductive support 13 and a solid polymer
electrolyte 15, support 13 being impregnated with solid polymer
electrolyte 15.
[0034] Referring now to FIGS. 2(a) and 2(b), support 13 can be seen
to be a generally sheet-like, unitary structure, preferably of high
mechanical strength, having a top surface 17 and a bottom surface
19. The thickness of support 13 may vary, depending upon the type
of use to which membrane 11 is put and the types of pressures
typically encountered by support 13 in such a use. For example,
where membrane 11 is used in an electrolyzer, support 13 preferably
has a thickness suitable for withstanding pressures of 2000-5000
psi. For most applications, support 13 has a thickness of about 1
.mu.m to 50 .mu.m, preferably about 7.5 .mu.m to 15 .mu.m.
[0035] As noted above, support 13 is preferably a rigid member; in
addition, support 13 is preferably chemically resistant to acid and
water hydrolysis at elevated temperatures. Materials suitable for
use as support 13 include, but are not limited to, silica, quartz,
glass, boron carbonate, silicon carbide, alumina, titania, silica
tungstate, sintered valve metal oxides (e.g., tantalum or niobium
oxide) and non conductive diamond or diamond-like coatings. A
comparison of the mechanical strength of some of the above-listed
ceramics to conventional PEM materials is provided below in TABLE
I.
TABLE-US-00001 TABLE I Material, condition Young's Modulus (Mpa)
NAFION .RTM. 112 PFSA membrane, dry 20.degree. C. 300 NAFION .RTM.
112 PFSA membrane, wet 80.degree. C. 70 Polytetrafluoroethylene
(PTFE) 400 SiO.sub.2 (VYCOR) 66,000 Al.sub.2O.sub.3 350,000 SiC
470,000
[0036] As can be seen, the ceramic materials (SiO.sub.2,
Al.sub.2O.sub.3 and SiC) are orders of magnitude stronger than PFSA
and PTFE.
[0037] A plurality of pores 21, preferably cylindrical in shape,
extend in a direct, i.e. straight-line, fashion from top surface 17
to bottom surface 19 of support 13. It should be stressed that the
base shape of the pore can be chosen from any two-dimensional
geometric shape distributed in either regular or irregular fashion.
As will be discussed further below, pores 21 are made by laser
micromachining. Each pore preferably has 21 a diameter of about 1
.mu.m to 200 .mu.m, with pores 21 constituting about 20% to 95%,
more preferably about 40% to 70%, of support 13.
[0038] The conductance of a membrane including such a porous
support can be easily estimated as:
1 G = Ts .sigma. A X + ( T - Ts ) .sigma. A ##EQU00001##
where G is the ionic conductance of the composite membrane, .sigma.
is the ionic conductivity of the solid polymer electrolyte, A is
the geometric area of the composite membrane, X is the percentage
of pores in the support, T is the thickness of the composite
membrane and T.sub.s is the thickness of the support.
[0039] As can be seen from the above equation, the conductance of
the composite membrane is inversely proportional to the percentage
of pores in the support. Thus, a support with 50% pores results in
a composite membrane with conductance equivalent to a homogenous
membrane twice as thick. To maximize the conductance of the
supported membrane without a sacrifice in mechanical properties, a
support with 50% pores may be fabricated.
[0040] In the present embodiment, pores 21 are arranged in a
uniform hexangular pattern over the entirety of support 13, such
pores 21 having, for example, a diameter of about 25 .mu.m and a
center-to-center spacing of about 40 .mu.m. It is to be understood,
however, that the present invention is not limited to the
above-described pattern of pores and may encompass a variety of
different patterns of pores. For example, as can be seen in FIG. 3,
there is shown a fragmentary top view of a support 13' having a
plurality of pores 21' that are arranged so that a lesser
concentration of pores 21' may be found in areas of higher membrane
stress (e.g., at the membrane edge 23 or in local "hot spots" 25)
and a greater concentration of pores 21' may be found
elsewhere.
[0041] Pores 21 (and 21') are made by lasing support 13 with
suitable laser light. Although either gas lasers or solid state
lasers may be used to create pores 21, gas lasers are preferred.
Within the class of gas lasers, excimer lasers are preferred over
CO.sub.2 lasers. This is because excimer lasers produce laser light
having a much shorter wavelength than that produced by CO.sub.2
lasers (.about.0.3 .mu.m for an excimer laser vs. .about.10 .mu.m
for a CO.sub.2 laser). Consequently, because of their shorter
wavelengths, excimer lasers directly excite the covalent bonds of
the support and decompose the support without creating as extreme
high-temperature conditions as is the case with CO.sub.2 lasers.
Additionally, due to their shorter wavelengths, excimer lasers can
create significantly smaller pores than can CO.sub.2 lasers.
[0042] Where a CO.sub.2 laser is used to micromachine pores into
the support, the whole laser beam is focused onto an area of the
support until the irradiated area is ablated. Where an excimer
laser is used, the relatively uniform beam intensity produced
thereby provides an alternative approach to pore formation:
near-field imaging. In near-field imaging, which is schematically
depicted in FIG. 4, a mask having a pattern is placed in the path
of the beam emitted by the excimer laser. The light transmitted
through the pattern of the mask is then focused by an imaging lens
onto the support, resulting in the mask pattern being projected
onto the support, with a corresponding pattern of pores being
formed in the support. As can readily be appreciated, near-field
imaging enables various alternative patterns to be projected onto
the support simply by using differently patterned masks.
[0043] Referring back to FIG. 1, solid polymer electrolyte 15 can
be seen to fill pores 21 and to cover thinly top surface 17 and
bottom surface 19 of support 13. Examples of suitable materials for
use as solid polymer electrolyte 15 include (i) polymer
compositions that contain metal salts; (ii) polymeric gels that
contain electrolytes; and (iii) ion exchange resins. In general, if
proton conductivity is required, a carboxylated, sulfonated or
phosphorylated polymer is preferably used as solid polymer
electrolyte 15. If hydroxyl ions are needed, a polymer containing
amino, imimo, ammonium, sulfonium, and phosphonium groups is
preferably used as solid polymer electrolyte 15. To enhance the
ionic conductivity of membrane 11, inorganic ionically-conductive
materials, such as metal oxide (e.g., TiO.sub.2), silicon oxide,
metal phosphates (e.g., zirconium phosphate) or heteropolyacids,
may be impregnated into the solid polymer electrolyte 15.
[0044] A preferred material for use as solid polymer electrolyte 15
is a perfluorosulfonic acid (PFSA) membrane, such as is
commercially available from DuPont (Wilmington, Del.) as
NAFION.RTM. PFSA polymer. Of the aforementioned NAFION.RTM. PFSA
polymers, particularly preferred are those having an equivalent
weight of 200 to 2000, even more preferably those having an
equivalent weight of 500 to 1200, the optimal equivalent weight
depending on the use to which membrane 11 is applied.
[0045] Various techniques may be used to couple solid polymer
electrolyte 15 to support 13. One such technique involves providing
the solid polymer electrolyte in the form of a solution/dispersion
(e.g., NAFION.RTM. 1100 in water or isopropanol) and then coating
support 13 with said solution/dispersion. Examples of suitable
coating techniques include gravure coating, immersion (dip)
coating, metering rod (Meyer bar) coating, slot die coating, rotary
screen and air knife coating. The optimal coating technique for any
particular case will depend on factors, such as instrument
complexity, thickness accuracy, operation efficiency, initial
investment, and the like. After the solution/dispersion is coated
onto the support, the coated support is heated at about 50.degree.
C. to 100.degree. C., preferably 80.degree. C., for about 5 minutes
to evaporate the solvent. If desired, one or more additional
coatings may thereafter be applied. Said one or more additional
coatings either may be of the same solution/dispersion previously
applied in order to build up the thickness of the solid polymer
electrolyte or may be different from the initial
solution/dispersion in order to obtain a composite membrane with a
multilayer electrolyte structure having desired properties. (An
example of a composite membrane possessing such a multilayer
structure is shown in FIG. 5, said composite membrane 51 comprising
a support 13, a first solid polymer electrolyte 53 and a second
polymer electrolyte 55.) After coating and drying each applied
layer or after coating and drying all applied layers, the layer or
layers are preferably cured by heating at a temperature greater
than the glass transition temperature of the ionomer (e.g.,
100.degree. C. to 400.degree. C., preferably 160.degree. C. for 15
minutes). Such curing, which serves to sinter or anneal the
ionomer, further enhances the mechanical properties of the
membrane.
[0046] If desired, mask coating technology may be used to create a
composite membrane wherein the solid polymer electrolyte is
confined to certain patches or regions.
[0047] As an alternative to coating, the solid polymer electrolyte
may be applied by spraying the polymer electrolyte
solution/dispersion onto support 13. Conventional spraying
techniques may be used for this purpose. Such spraying is
preferably performed at 80.degree. C. and does not require a
subsequent solvent evaporation step. Micro-spraying may be used to
create solid polymer electrolyte patches on the support, such
patches, if desired, being far smaller than those capable of being
produced by masked coating techniques.
[0048] Still another technique for incorporating the solid polymer
electrolyte 15 into support 13 involves a membrane extrusion
technique. Such a technique comprises providing a solid polymer
electrolyte in the form of a thin membrane, stacking the thin
precursor membrane on the top and/or bottom surfaces of support 13,
and then pressing the stack together at an elevated temperature,
preferably above the melting point or glass transition temperature
of the membrane, so that the membrane melts and is forced into
pores 21. In those instances in which the membrane does not melt
upon heating, but rather, degrades upon heating, a membrane
precursor may be heated and forced into the pores and thereafter
may be chemically converted to the corresponding solid ionomer. For
example, if one wished to fill pores 21 with a PFSA (which does not
melt, but instead, degrades upon heating), one could use a PFSA
precursor in which the acid groups are replaced with sulfonyl
fluoride groups. In such a case, once the sulfonyl fluoride
precursor has melted and has been forced into pores 21, a base may
be added to the PFSA precursor to convert the PFSA precursor into
PFSA by base hydrolysis. Where support 13 is made of alumina or
another ceramic material that degrades in the presence of a strong
base (i.e., a base that donates an OH.sup.- group), a Lewis base
(i.e., a base that accepts an H.sup.+), such as imidazole, is
preferably used to convert the sulfonyl fluoride PFSA precursor
into PFSA.
[0049] Still yet another technique for incorporating the solid
polymer electrolyte 15 into support 13 involves filling pores 21
with a corresponding monomer and then polymerizing the monomer in
situ to form the desired solid ionomer. Such polymerization may be
effected with the use of an initiator (e.g., vinyl) mixed in with
the monomer or by radiation (e.g., UV radiation).
[0050] Referring now to FIG. 6, there is shown a schematic section
view of a third embodiment of a solid polymer electrolyte composite
membrane constructed according to the teachings of the present
invention, said solid polymer electrolyte composite membrane being
represented generally by reference numeral 111.
[0051] Composite membrane 111 is similar in many respects to
membrane 11, the principle difference between the two membranes
being that, whereas membrane 11 includes a ceramic support 13 whose
pores 21 are formed by laser micromachining, membrane 111 includes
a ceramic support 113 whose pores 121 are formed by the controlled
electrochemical oxidation (i.e., pitting) of a sheet of the base
metal (e.g., aluminum, titanium, etc.). A top view of support 113
is shown in FIG. 7. As can be seen, support 113 has a
honeycomb-like arrangement of pores 121. WHATMAN ANODISC membrane
filter, which is commercially available from Whatman International
(United Kingdom) and is marketed for filtration purposes, is made
of alumina and may be used support 113.
[0052] Pores 121 made by pitting a sheet of the base metal may have
a diameter as small as about 0.01 .mu.m. However, it should be
noted that, where the diameter of pores 121 is less than about 0.1
.mu.m, pores 121 cannot easily be filled using a solution or
dispersion of the solid ionomer. Consequently, preferred techniques
for filling such small pores include the hot-extrusion and in-situ
polymerization techniques described above.
[0053] The total thickness of membrane 11 or 111 is preferably
about 5 to 300 .mu.m, more preferably 10 to 75 .mu.m, with the
thickness of the membrane being governed by application
requirements. Generally, a water electrolyzer requires a thicker
membrane due to its high differential pressure while an ultra-thin
membrane is suitable for super capacitors since no dynamic pressure
is involved for their operation.
[0054] Membrane and electrode assemblies (MEAs) comprising the
composite membrane of the present invention can be fabricated by
pressing a precast Pt-supported on carbon/ionomer ink onto each
side of the composite membrane. The foregoing method is typically
referred to as the decal transfer method.
[0055] One of the advantages of the composite membrane of the
present invention is that catalyst ink can be directly coated or
sprayed onto the top and bottom surfaces of the membrane. This
direct coating of the catalyst ink is not practical for
conventional ionomer membranes since such membranes change
dimension when contacted with the ink. Since the composite membrane
of the present invention has excellent dimensional stability when
contacted with swelling agents, such as water or alcohols, the
catalyst ink can be directly applied to the membrane.
[0056] Another approach that may be used to fabricate an MEA using
the composite membrane of the present invention involves a
technique called "catalyst on diffusion media." The diffusion
medium of this technique is a porous electrically-conductive
material, which is typically in the form of a thin sheet.
Optionally, a microporous layer prepared from carbon black and a
polymer binder may be applied to the diffusion medium. The catalyst
is then sprayed onto the diffusion medium to form a diffusion
electrode. A catalyst-loaded diffusion electrode is then pressed
onto each side of the composite membrane to form a full MEA.
[0057] The following examples are provided for illustrative
purposes only and are in no way intended to limit the scope of the
present invention:
Example 1
[0058] A plurality of pores were formed in a piece of 25 .mu.m
thick silica film using an excimer laser and near-field imaging.
The diameter of each pore was 30 .mu.m, and the distance between
the centers of the pores was 60 .mu.m. NAFION.RTM. PFSA solution,
with an equivalent weight of 1100, was coated onto the porous film,
and the product was then heated to dry off the solvent from the
coated PFSA solution and to cure the PFSA polymer. The resultant
composite membrane had a thickness of approximately 32 .mu.m. The
wet through-plane conductivity of the membrane was 0.05 S/cm, as
compared to 0.10 S/cm for the neat ionomer.
Example 2
[0059] A 25 .mu.m NAFION.RTM. precursor membrane in the sulfonyl
fluoride form was pressed into a 60 .mu.m WHATMAN ANODISC filter
having a 1.0 .mu.m pore size. Such pressing was effected at
350.degree. C. at 300 psi for 1 hour. Conversion of the sulfonyl
fluoride form of the membrane was then effected by hydrolyzing
overnight with imidazole at 60.degree. C. The resulting wet room
temperature through-plane-conductivity of the membrane was 0.04
S/cm, as compared to 0.10 S/cm for the neat ionomer.
[0060] The embodiments of the present invention recited herein are
intended to be merely exemplary and those skilled in the art will
be able to make numerous variations and modifications to it without
departing from the spirit of the present invention. All such
variations and modifications are intended to be within the scope of
the present invention as defined by the claims appended hereto.
* * * * *