CA1330547C

CA1330547C - Composite membrane useful as an electrode separator

Info

Publication number: CA1330547C
Application number: CA000533959A
Authority: CA
Inventors: John Anthony Cook; Iain Stephen Smith; Raymond William Singleton
Original assignee: Scimat Ltd
Current assignee: Freudenberg Nonwovens Ltd
Priority date: 1986-04-07
Filing date: 1987-04-06
Publication date: 1994-07-05
Anticipated expiration: 2011-07-05
Also published as: JPS63503074A; EP0263159A1; IL82123A0; GB8608430D0; WO1987006395A1; DE3781081D1; IL82123A; EP0263159B1; KR880701469A; JP2520928B2; DE3781081T2

Abstract

ABSTRACT OF THE DISCLOSURE

A process for making a polymeric ion exchange membrane comprises providing a membrane comprising a first polymeric material which defines a porous matrix, and a second material which includes a photoinitiator and which at least partially fills, and thereby blocks, the pores of the matrix, and exposing the membrane to UV radiation so as to polymerise and to crosslink the second material, the thickness of the membrane being less than 250 µm. The membrane is particularly useful as an electrode separator in an electrochemical device, allowing ionic conduction, and presenting a barrier to electrode particles, between the electrodes of the device.

Description

~3~7 COMPOSITE MEMBRANE

This invention relates to a process for making a composite membrane and to a composite membrane, which is particularly useful as an ion-exchange membrane for use for example as an electrode separator in certain types of electrochemical device.
In certain types of electrochemical device, in par-ticular of electrochemical cell, lifetime can be limited by migration of electrode material in particulate form and in solution onto the opposing electrode and sub-sequent self-discharge. Another problem arises in in secondary cells on recharging when loosely attached material is deposited on the anode, often in the form of dendrites. These problems can be overcome by use of an electrode separator which provides a continuous barrier to electrode particles and which allows ionic conduc-tion.
US-2965697 (Duddy) discloses a battery diaphragm which consists of a porous matrix in which pores are filled with crosslinked polyacrylic acid. The diaphragm is made by impregnating a porous matrix, for example of polyethylene, with a mixtue of methacrylic acid, divinyl benzene and benzoyl peroxide, and then applying heat to initiate polymerisation of the acid. The polymerisation reaction is exothermic and once it has been initiated, it is necessary to apply heat moderating means in order to ensure that the rate of reaction is controlled.
The process described in US-2965697 is a slow and inconvenient batch process, and requires the use of the above-mentioned heat moderating means. However, even with such apparatus, the process is particularly dif-ficult to control so as to produce diaphragms with con-sistent properties.

f~ 7 We have devised a convenient process for making a composite membrane which involves the use of irradiation, particularly using ultraviolet (W) radiation to effect crosslinking of an ion exchange material within the pores of a porous matrix.
Accordingly in a first aspect, the present invention provides a process for making a composite polymer membrane, which comprises: (a) providing a membrane comprising a first polymeric material which defines a porous matrix, and a second material which includes a photoinitiator and is capable on exposure to W radiation of polymerization, and which at least partially fills, and thereby blocks, the pores of the matrix; and (b) exposing the membrane to W radiation so as to polymerise and to crosslink the second material; the thickness of the membrane being such that the membrane material is no more than 250 ~m. With the proviso that when the thickness of the membrane is greater than 150 ~m, the membrane is irradiated from both sides.

The process of the invention has the advantage that it can be performed continuously on a continuous strip of the composite ;~
membrane, i.e. the first and second materials, by passing the strip under a source of radiation rather than by exposing a membrane to heat. The sheet may be in the form of a film, tape, or ribbon, or in the form of a tube. Other sheet-like forms may be used depending upon the application.
Preferably, the sheet will be flexible. The source of radiation will preferably provide W radiation which is cheap and convenient to use with small safety risks. It is envisaged however that gamma radiation such as from a Co~
source or electron bombardment may be used as alternative radiation sources. An appropriate initiator will generally be mixed with the second material for initiation of the crosslinking reaction, and where necessary for initiation of 35 polymerisation of the second material. When W radiation is -used, a photoinitiator will be mixed with the second -~

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- 2a -material. Suitable photoinitiators are well known in the .
prior art such as acetophenone, propiophenone, xanthone, fluorenone, 3- or 4-methoxyacetophenone, 2-hydroxy-2-methyl-l-phenylpropan-1-one, :

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_ 3 _ RK299 1-(4-isopropylphenyl)-2-hydroxy-2-methylpropan-l-one and 1-hydroxycyclohexylphenyl ketone etc.
Furthermore, the use of irradiation, especially UV
irradiation, has the advantage that the crosslinking step is readily controllable, it being possible to control the degree of crosslinking by selecting an appropriate exposure of the membrane to the radiation.
Thus it is possible to produce continuous lengths of irradiated membrane with consistent properties, and to ensure that those properties are reproduced in sub-sequent lengths.

UV radiation has the further advantage that its energy is suitable for effecting the crosslinking of ;~
thin films; radiation from other sources with higher energy is absorbed only slightly by thin membranes.
A yet further advantage of UV radiation is that it has been found to increase the wettability of a membrane, possibly as a result of ionisation of its sur-face. This is useful because it can facilitate sub-sequent reaction of components of the membrane: for example, it can facilitate neutralisation of acrylic acid when used as the second material of the membrane.
The ability to control the degree of crosslinking has been found to lead to an important subsidiary advan-tage in that fundamental properties of the membrane can conveniently be altered. These include the ionic con-ductivity through the membrane (when used as a separator in an electrochemical cell) and also the barrier proper-ties of the membrane for example towards dissolved .
electrode material. Both the barrier properties and the conductivity depend inter alia on the extent to which the membrane swells on contact with a liquid such as the 13 3 ~
_ 4 _ RK299 electrolyte of an electrochemical cell, particularly analkaline electrolyte: a swollen membrane will have a high conductivity but poor barrier properties compared with a relatively less swollen membrane, since liquid electrolyte can more easily be absorbed into the membrane when it is swollen. The degree of swelling is affected by the density of the crosslinks in the second material of membrane. Thus, simply by altering the crosslink density, it is possible to vary the barrier properties and ionic conductivity of the membrane, such alteration being particularly simple to effect in the method according to the present invention. This allows membranes to be made conveniently to suit the require- -ments of particular applications. For example in the case of alkaline electrochemical cells the barrier pro-perties required of the membrane are dependent to some extent on the solubility of electrode material in the cell electrolyte. Thus, the present invention enables a separator to be made conveniently for a mercury/mercuric oxide cell that has a higher conductivity than one for a silver/silver oxide cell, which is desirable because of the lower solubility of mercuric oxide in alkaline solu-tion. The present invention therefore enables membranes to be made conveniently to suit each particular applica-tion with optimum conductivity.
Preferably, the pores defined by the matrix of the first material are blocked over substantially the entire area of the membrane. It is particularly preferred that the pores be substantially filled with the second material, it being understood that this does not necessitate the exposed surface of the second material in the pores being exactly in line with the main surface of the membrane, and the degree of filling may vary somewhat depending on the shape, size, and tortuosity of A~. . ~ : ' . ' , ~ 3 ~ 7 ,r~
5 _ RK299 the pores. Pores which are much less than completely filled by the second material within them may be suitable for some purposes, provided that the pores remain substantially blocked at some point within their length, in the ~ense that there is no passage within the pore whereby fluids may readily pass the blocking "plug"
without having to permeate the plug and/or the surrounding wall material of the pore.
For optimum barrier properties, it is preferred that at least 20~ of the volume of the pores within the matrix of the first polymeric material is filled by the second material, more preferably at least 75~, espe-cially at least 95~
- '- :
In a preferred embodiment of this invention, the second material in the pores of the matrix is mixed with a crosslinking agent to effect the crosslinking of the ~econd material. The density of crosslinks can be ~;
affected by the proportion of crosslinking agent to -second material. Preferably the mole ratio of crosslinking agent to second material is at least 0.1~ 0 more preferably at least 0.5~, especially between 1~ and 15~. The need for a crosslinking agent will depend on the particular second material that is selected, and in some cases on the intended end use of the article.
The second material may be selected according to -~
the intended end use of the membrane, polymeric - materials (including homo- and copolymers and mixtures thereof) being preferred. Materials which may be used to form a second polymeric material include ethyleni-cally unsaturated acids and their esters for example acrylic acid, methacrylic acid, ethyl acrylate and methylacrylate, maleic acid, maleic anhydride, acryla-mide N-monomethyl and N,N-dimethylacrylamide, vinyl ace-.. ~ :: . . : . . . : , .

3~05~7 tate, vinyl pyridines for instance 2-vinylpyridine, 2-methyl-5-vinylpyridine and 2-vinyl-5-ethylpyridine.
Sulphonation of suitable second materials (e.g. styrene monomer or polymer) for ion exchange purposes may be useful. Polymers or copolymers of ethylenically unsa-turated acids are preferred for ionically active sheets such as electrochemical cell electrode separators, acry-lic and methacrylic acid polymers of copolymers being especially preferred. In any case, second materials which are polyelectrolytes may be selected to provide the article with an ion-exchange capacity, preferably greater than 1 milliequivalent per gramme (meq.g-1), preferably greater than 3 meq.g-1 and ideally greater than 5 meq.g-1.

The second material can conveniently be supplied to the pores of the matrix of the first material in monomer form and then polymerised in situ when the membrane is irradiated. This is particularly advantageous when the second material is a liquid when monomeric and a solid when polymerised since it enables the pores within the matrix to be filled substantially completely with the polymerised second material simply by impregnation, for example under vacuum, with the liquid monomer.
When the second material is polymerised by irra-diation, polymerisation and crosslinking reactions com-pete for the monomeric second material. By selecting a crosslinking agent with an appropriate reactivity towards the monomeric second material, compared with the reactivity of that material in polymerisation, the den_ sity of crosslinks can be adjusted to suit a particular application, as described above.
Surprisingly, it has been found that certain crosslinking agents react with preferred second 7 ~ 33~7 RK299 materials such as acrylic acid derivatives at such at rate as to give crosslink density which renders the crosslinked second material inert to aqueous acid and base; such crosslinking agents generally form a secon-dary radical (whether conjugated or non-conjugated) or a tertiary non-conjugated radical when irradiated. Such particularly preferred crosslinking agents include triallyl isocyanurate (TAIC), triallyl cyanurate (TAC), 1,5-hexadiene-3-ol, 2,5-dimethyl-1,5-hexadiene, 1,5-hexadiene, 1,7-octadiene, 3,7-dimethyl-2,6-octadiene-1-ol (Nerol~) and diacrylates such as polyethylene glycol diacrylate and dimethacry- -late and triethylene glycol dimethacrylate. ;~
The use of irradiation, particularly UV radiation, enables the process of the present invention to be carried out more quickly and more efficiently than the thermally initiated crosslinking reactions used in prior art processes. Thus the crosslinking reaction can, in favourable circumstances, be completed in less than 30 seconds.
The second material, together with initator and crosslinking agent when present, may be introduced into the pores of the matrix of the first polymeric material in solution. It is however desirable to use a solution of the second material which polymerises and is crosslinked at an acceptable rate without unacceptable phase separation of the solution. For example, a solu-tion consisting of the following could be used (percentages given by weight):
acrylic acid (reactive monomer) 60 to 95~ -crosslinking agent 0.5 to 25 photoinitiator 0.1 to 5 water up to about 60 .,.,,, ~ : , ., . ... , . . .. : -~ 3 3 ~ J RK299 The matrix of the first material is preferably formed by removal, preferably by liquid extraction, of a removable material dispersed therein. Liquid extraction of polyethylene oxide from an article comprising a mix-ture of polyethylene and polyethylene oxide is a pre-ferred example, other possibilities including liquid extraction of solid fillers from sheet comprising the filler and a polymer such as polyethylene, the filler being for example lithium carbonate and the extraction medium being hydrochloric acid; extraction of polyviny-lacetate from polyvinylchloride sheet; or extraction of ethylene/vinylacetate copolymer from isotactic polypropylene.
It will be understood that when the term porous is ~ -used to describe the matrix of the first material, the term is applicable to a component of a membrane which consists of interpenetrating phases.
The membrane made by the present method preferably has a thickness of less than 250 micrometres, more pre-ferably less than 200 micrometres, and especially less than 150 micrometres. For use as an electrode separator in an electrochemical device such as a cell, it is pre-ferred that the thickness of the membrane is from 25 to ~ -100 micrometres, and it is an advantage of the membrane made by the present method that such a relatively thick barrier without direct open passages through it can be used to resist penetration by, for example, silver oxide in silver-zinc cells, or by dendrite growth, while surprisingly lowering the electrical resistance by as much as 50~ compared with much thinner (25 to 30 micro-metres) known membranes in which acrylates are merely radiation-grafted onto a substantially non-porous polymer sheet to improve its characteristics. Other known membranes in which acrylic acid is grafted onto r~ f` 1 3 ~ 7 _ 9 _ RK299 the pore surfaces without blocking the pores require a further absorbent layer to resist penetration, the need for which layer is eliminated by the present invention. ;
The present invention thus allows membranes to be made which are sufficiently thick to provide a barrier in an electrochemical cell. However, the membranes are ~ ¦
not so thick that they are inflexible; indeed, the fact that the present method allows the crosslink density in ~ -the second material to be controlled al~s enables the flexibility of the membrane to be optimised. -~

Extraction methods of forming the matrix of the first polymer are preferred because the pores produced ;~
tend to have a higher tortuosity factor (defined as mean ~ ;
path length/article thickness), determined by resistance ~ -measurements as known per se, than pores produced by stretching or perforation techniques. Higher tortuosity is thought to be desirable in order to help retain vola-tile polymerisable materials such as acrylic acids in the pores until polymerisation is effected, tortuosity factors greater than 2, preferably greater than 4, more preferably greater than 6, and even greater than 7 or greater than 8 are therefore desirable. Mean diameter and porosity can be measured by for example, mercury intrusion porosimetry (ASTM-D-2873-70), and the length by eIectron microscopy.
However made, it is preferred that the matrix of the first material is microporous, such that the details , of its structure are discernable only by microscopic examination. It is particularly preferred that the structure of the pores is so fine the discernment thereof is possible only by use of electron microscopy techniques, which can resolve details of structure below 5 micrometres.

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~,.. ",~ ,,.,",., ~ ;":~," ,. ,., " ,' , ",~,1" ~ ", ~ .-~ 3 ~ ~ ~ 7 7 _ lo - RK299 ¦ Preferably, the volume of the pores is at least ¦ 10~, more preferably at least 30% in order to achieve satisfactory conductivity. A pore volume of 80 to 90 is preferred for many applications.
A particularly preferred embodiment of the present process includes the step of forming the membrane by extruding a blend of the first and second materials which can then be irradiated to crosslink the second material. This method of forming the membrane is appropriate to second materials which are stable, in ;
particular non-volatile, at extrusion temperatures.
Thus second materials that are polymeric prior to incor- -poration in the membrane may be incorporated in this way even if they would be for example too volatile when -~
monomeric. The formation of the membrane by this pro-cess has the significant advantage that pores in the matrix of the first material are filled and defined by the second material when the matrix itself is formed; it is not necessary first to create the porous matrix and then to fill the pores with the second material.
Appropriate processing aids will be included in the blend of first and second materials for the extrusion, such as plasticising agents. Advantageously, a crosslinking agent that is included in the blend to crosslink the second material may also function as a plasticising agent in the extrusion step.
Preferably, the second material after irradiation is more permeable (i.e. has a faster diffusion rate) than the first polymeric material to selected ions encountered when the membrane is in use; for example when in use a~ a cell electrode in an alkaline electrochemical cell, the second material will pre- ;~ -ferably be relatively permeable to hydrogen and/or '' ~' :::

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hydroxide ions Both the first and second materials should be substantially inert towards fluids encountered by the membrane when in use, although beneficial interactions such as swelling when desired are not excluded. "Inert~ as used herein means that the ~-~
materials are not destroyed, disintegrated or otherwise unacceptably affected by such fluids. The suscep~
tibility of the second material to removal from the membrane made by the present method is believed to be reduced as a result of grafting of the second material on to the matrix of the first material, simultaneously with the crosslinking reaction.
In another aspect, the present invention provides an electrochemical device, such as an electrochemical cell, which comprises an anode, a cathode, a liquid electrolyte, and an electrode separator which is a com-posite polymer membrane that is made by the method of the invention.
In addition to its use as a separator in an electrochemical cell, the membrane of the present inven-tion may also be used in other applications where ion exchange properties are required. By appropriate selec-tion of second materials, the membrane may be used in biological applications, for example in dialysis.
Specific embodiments of the invention will now be described by way of example, using a porous film made as follows.
Medium density polyethylene granules (Sclair 8405~
from Du Pont) and polyethylene oxide (Polyox WSRN 750~ :
from Union Carbide) were compounded using a Baker -Perkins twin screw extruder to give a blend containing 40 parts of polyethylene and 60 parts by weight .--` ^~ ~ $'~ ~ 7 polyethylene oxide. The compound was then blown into a 100 micron thick film using conventional blown polymer film techniques. The die gap was 0.65 millimeters and the die temperature 210C. The blow ratio was 2 The blown film was then immersed in water to remove the polyethylene oxide by dissolution. The film was then removed from the water and dried to leave a micro~
porous web of polyethylene.
Using mercury intrustion porosimetry (ASTM
D2873-70) the porosity of the microporous film was found to be 50~ and the average pore diameter was 1 micron.
The film was found not to be wetted by water or alkaline electrolytes. Using the method described in "Characteristics of Separators for Alkaline Silver Oxide Secondary Batteries", AD447301 US Air Force Manual, the resistance of the film after 24 hours in 40% ww potassium hydroxide (KOH) at 30C was found to be 11.9 ohm.cm2.
Example 1 A battery separator was prepared by taking a con-tinuous length of the microporous film (width 10 cm) described above and vacuum impregnating the film with a solution of the following composition (all amounts per-cent by weight).
Acrylic Acid (supplied by Aldrich) 63 Triallyl Isocyanurate -~
(Nippon Kasei Chemical Co Ltd) 5 Daracur 1116~ (Merck) 5 Water 27S
(1) Daracur 1116 is ~ -1-(4-Isopropylphenyl)-2-hydroxy-2-methypropane-1-one, a ~,,~ ", r~ ~ 3~ 7 photoiniator.
The percentage mole ratio of the crosslinking agent to acrylic acid was 2.3~
Care was taken to make sure that all the pores within the film were completely filled with the solu-tion. The impregnated solution was then photopoly-merized within the pores by passing the film at a speed of 0.4 metres per minute under a 15.4 cm long 500 watt medium pressure mercury vapour UV lamp (~anovia Type UVS
500). The distance between the lamp and the microporous film was 6 cm and the total irradiation time for any part of the film was 22 seconds.
The above process of impregnation and UV irra-diation was repeated on the previously unexposed side of -the film.
After irradiation the treated film was washed in methanol and then water to remove unreacted monomer and photoinitiator. The film was then further treated in 5~ wJw KOH at 60C for 16 hours to convert the poly-merized acrylic acid into its potassium ion form.
Finally, the film was washed again with water before being allowed to dry within a constant 50% relative humidity environment.
: .
The separator thus produced was strong and flexible and had a final thickness of 100 micrometres. The moisture content as determined by drying at 100C was 15~. Chemical analysis showed the separator contained -~
43~ acrylic acid with respect to its dry acid form. The ion exchange capacity was 6 meq.g-1. Table 1 below lists some additional characteristics of the separator.
These characteristics were determined according to the methods described in "Characteristics of Separators for ~ .:

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Alkaline Silver Oxide Secondary Batteries", AD447301 US
Air Force Manual.
TABLE l Resistance 0.145 ohm cm2 (40~ ww KOH at 30C) Electrolyte Diffusion 0.21 mmol cm~2 min~1 (10 Molar KOH gradient at 25C) Dimensional change (40% KOH at 30C) Length +6%
Width +15%
Thickness +50S
Electrolyte Absorption 160%
(40% ww KOH at 30C) Oxidation Resistance 2% ~ :.
(weight loss, Alkaline Permanganate) .~ :
Barrier to Ag20 Very good Example 2 : Additional battery separators of thickness 50 microns and 200 microns were prepared according to the -~
method described in Example 1. The resistance of these separators in 40% ww KOH at 30C is given in Table 2. -~

Separator thickness Resistance (micrometres) (ohm cm2) 0.085 200 0.220 .. , . , .. ,, . ., ,~. . .
-.;
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3~`ia7 _ 15 _ RK299 Example 3 .
The long term stability of the battery separator was evaluated by storing pre-weight samples made according to Example 1 in 40~ ww KOH at 60C for various periods of time. After storage the samples were dried, re-weighed to determine any weight loss and then their resistance in 40~ ww KOH at 30C determined. The results are shown in Table 3 below and clearly demonstrate the stability of the separator to strong alkaline electrolytes.

Storage Time Weight Loss Resistance (weeks) (~) (ohm cm2) 0 0 0.145 2 0 0.167 4 0.7 0.154 6 2.5 0.125 8 3.5 0.157 Example 4 This examples demonstrates how the proportion of crosslinking agent to acrylic acid in the impregnation solution can a1ter the properties of the separator by changing the density of crosslinks.
A battery separator was prepared according to the method described in Example 1 using an impregnation solution of the following composition.
Acrylic acid 68 Triallyl Isocyanurate 15S
~; .

` ~

Daracur 1116 6 Water The percentage mole ratio of the cross-linking ~
agent to acrylic acid was 6.4~. `
The separator thus produced was strong and flexible and had a final thickness of 110 microns. The moisture content was 15%. The separator contained 35~ acrylic acid and had an ion exchange capacity of 4.9 meq. g-1.
Table 4 below lists some additional characteristics of the separator.
TABLE 4 ~ `
Resistance 0.830 ohm.cm2 ;
. ........................................ ........................... .. ~::
Dimensional Stability length +3%
width +5% ... .
thickness +7% `-Electrolyte Absorption 81%
Oxidation Resistance 2% -: .-. .
Barrier to Ag20 Very good The separator showed a weight loss of only 7% after 8 weeks storage in 40% ww KOH at 60C.
A comparison of the date in Table 4 and Table 1 tExample 1) clearly shows the effect of increased den~
sity of cross-links on separator properties. Of par-ticular note is increased resistance and a reduction in ~
dimensional changes in alkaline electrolyte. ~`
Example 5 -. :

~ .
,, ,. ,,, . . . . . . -f~ 3'~;7 _ 17 _ RK299 Battery separators were prepared according to the method described in Example 1 using the cross-linking agents 1,5-hexadiene, 1,5-hexadiene-3-ol and 3,7_dimethyl_2,6_octadiene_1-ol (all supplied by Aldrich Chemical Co Ltd). The ~ compositions by weight of the impregnation solutions were as follows:
Composition No. 1 2 3 Acrylic Acid 65.5 64 60.5 1,5-hexadiene 9-5 1,5-hexadiene-3-ol - 11 3,7-dimethyl-2,6-octadiene-1-ol - - 16.2 Daracur 1116 5 5 4-7 Water 20 20 18.6 The percentage mole ratio of the cross-linking agent to acrylic acid was 12.5~ for all solutions.
The separators thus produced were all strong and flexible and had a final thickness of 90 to 100 micron.
Additional properties of the separators are given in Table 5 below.

Composition No. 1 2 3 Acrylic Acid Content (~) 35 30 27 Resistance (ohm.cm2) 0.310 0.810 1.240 Dimensional Stability (%) length +1.2 +1.9 -0.3 width +12.6 +7.4 +0.5 thickness +72 +56 +19 Electrolyte Absorption (~) +206 +169 +132 The stability of these separators to 40~ ww KOH was determined according to the procedure described in . .: ~: :: - ~: :- :-, . : .

~ 7 ~ _ R~299 Example 3. The results of these studies are presented below and show that all the cross-linking agents produce separator stable 40~ ww KOH even at 100C.

Temperature Storage Time Weight Loss (0C) (Days) Cross-linking Agent 1,5-Hexadiene 60 26 3.7 100 9 18.9 ~-1,5-Hexadiene-3-ol 60 26 3.2 -~
100 9 2.1 ~-3,7-dimethyl-2,6- 60 26 4.9 -~
octadiene-1-ol 100 9 15.1 ~ -~
~' " ' ';
Example 6 ; ~., Battery separators were prepared according to the method described in Example 1 except the crosslinking -agent triallyl isocyanurate was replaced by either triallyl cyanurate (Nippon Kasei Chemical Co Ltd) or polyethylene glycol 200 diacrylate (Sartomer product SR259~). The stability of these separators to alkaline electrolyte was determined according to the procedure described in Example 3. The result of these studies are presented in Table 4 below and show that both crosslinking agents are unsuitable for use with alkaline electrolytes.

~ .
Crosslinking Storage Time Weight Loss Resistance ~; Agent (Days) (~) (ohm cm2) ..
:
;

~,: . , : . . .

~ " ,': :.': ' :'~ ~:~` '- ' : , ' ~ ~33~7~7 Triallyl Cyanurate 0 0 0.157 1 44.7 1.38 2 46.2 1.45 , Polyethylene glycol 0 0 0.123 200 diacrylate 4 60 15.5 Example '7 The resistance and stability of the separator materials described in Examples 1, 4, 5 and 6 were eva-luated in 28~ ww sulphuric acid (H2S04). All the separators were found to be stable in the acid with re istance of about 3 ohm cm 2.
Comparative Example Using the microporous film described above, a bat-tery separator was prepared according to the method given in US-2965697. The polymerisation reaction was carried out using the heated platen technique and took 20 minutes to complete. The impregnation solution had the following composition (percentage by weight).
Benzoly Peroxide (Aldrich Chemical Co Ltd) 3.4 Acrylic Acid 85.7 Triallyl Isocyanurate 10.9 The percentage mole ratio of t~he crosslinking agent to acrylic acid was 3.7~.
~; The separator thus produced was strong but rigid.
It had à thickness of 105 micron and a moisture content of 15.6S. Analysis showed the separator contained 51 acrylic acid. The ion exchange capacity was 7.1 '"';,''' ' .: ~

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13 3 0 ~ 7 , . . ....

.~, :. ,.
meq.g~1. The separator resistance was 4.83 ohm.cm2, ;-~
which was too high to make it of any practical use in an alkaline cell.
For co~parison, a battery separator was prepared according to the method of the present invention using an impregnation solution with the same percentage mole ratio of crosslinking agent to acrylic acid as that described above. The separator thus produced was strong and flexible with a thickness of 90 micron. Its moisture content was 15.6~ and it contained 43~ acrylic acid. The ion exchange capacity was 6.0 meq.g-1. The separator resistance was 0.850 ohm.cm2 making it suitable for use in alkaline cells.

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Claims

1. A process for making a composite polymer membrane, which comprises:

(a) providing a membrane comprising a first polymeric material which defines a porous matrix, and a second material which includes a photoinitiator and is capable on exposure to UV radiation of polymerization, and which at least partially fills, and thereby blocks, the pores of the matrix; and (b) exposing the membrane to UV radiation so as to polymerize and to crosslink the second material;

the thickness of the membrane being no more than 250 µm.

with the proviso that when the thickness of the membrane is greater than 150 µm, the membrane is irradiated from both sides.

2. A process as claimed in Claim 1 wherein the thickness is no more than 150 µm.

3. A process as claimed in Claim 1, wherein the thickness is from 25 to 100 µm.

4. A process as claimed in any one of Claims 1 to 3, which includes the steps (i) of forming the porous matrix from a mixture of the first polymeric material and a pore forming material, and (ii) removing the pore forming material.

5. A process as claimed in any one of claims 1 to 3, which includes the steps (i) of forming the porous matrix from a mixture of the first polymeric material which comprises polyethylene and polyethylene oxide, and (ii) removing the polyethylene oxide by liquid extraction.

6. A process as claimed in any one of Claims 1 to 3, which includes the step of impregnating the porous matrix with the second material before the irradiation step.

7. A process as claimed in claim 1, in which the second material is mixed with a crosslinking agent.

8. A process as claimed in claim 7, in which the mole ratio of crosslinking agent to the second material is at least 0.1%.

9. A process as claimed in claim 7, in which the crosslinking agent forms a secondary radical or a tertiary non-conjugated radical when the membrane is irradiated.

10. A process as claimed in any one of claims 1 to 3, in which the second material comprises an ethylenically unsaturated acid or an ester thereof.

11. A process as claimed in any one of claims 1 to 3, in which the second material and the conditions under which it is irradiated are selected to provide the membrane with an ion exchange capacity of greater than 1 milliequivalent per gramme.

12. Use of a composite polymer membrane produced by a process as claimed in any one of claims 1 to 3 and 7 to 9, for making an electrochemical device, comprising immersing the membrane, together with an anode and a cathode, in a liquid electrolyte.

13. Use of a composite polymer membrane produced by a process as claimed in any one of claims 1 to 3 and 7 to 9, as an electrode separator in an electrochemical device further comprising an anode, a cathode and a liquid electrolyte.