JP2017114122A - 強化複合膜及びその製造方法 - Google Patents
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Abstract
【解決手段】多孔性支持体層110と、多孔性支持体層110の一面又は両面上に形成された電解質膜層120、120’を含み、多孔性支持体層110の少なくとも一部に電解質が含浸された、強化複合膜100及び離型フィルム上に電解質膜120,120’を形成する電解質フィルムの製造ステップと、多孔性支持体110の一面又は両面に前記電解質フィルムを配置する配置ステップと、複合膜100を形成するように前記電解質フィルムの電解質膜120,120’を多孔性支持体110の一面又は両面に転写する転写ステップと、を含み、前記転写ステップは、ロールプレス工程によって行われ、前記転写ステップで多孔性支持体の少なくとも一部に電解質が含浸される、強化複合膜100の製造方法。
【選択図】図1A
Description
本発明の一実施形態による前記強化複合膜は、高分子電解質膜、水電解用高分子電解質膜、レドックスフロー電池電解質膜、大容量エネルギー貯蔵装置電解質膜、塩分濃度差発電電解質膜、淡水用分離膜、気体分離用分離膜、又は、浄水処理用分離膜であり得る。
本発明は、多層の強化複合膜の連続工程及び大量生産が可能であり、生産時間及び生産コストを削減できる強化複合膜の製造方法を提供することができる。
化式4の炭化水素系高分子であるポリフェニルスルホン高分子(イオン交換容量:1.30meq/g乾燥樹脂、xは20、yは5、n=5以上)をNMPに完全に溶解して10濃度%(w/v)の電解質溶液を製造した。前記製造された電解質溶液は、PET離型フィルム上にソリューションキャスティングした後、70℃のホットプレートで8時間の間溶媒を蒸発させてから120℃で4時間をさらに乾燥して7±3μmの厚さの電解質膜が形成された電解質フィルムを製造した。その後、塩酸に酸処理して陽子形態の電解質を製造した。
過フッ素化界高分子であるナフィオン懸濁液(デュポン社製、製品番号:DE2021)をNMPで置換して、10濃度%(w/v)の電解質溶液を製造した。前記製造された電解質溶液は、PET離型フィルム上にソリューションキャスティングした後、70℃のホットプレートで8時間の間溶媒を蒸発させてから120℃で4時間をさらに乾燥して7±3μmの厚さの電解質膜が形成された電解質フィルムを製造した。
ポリテトラフルオロエチレン多孔性支持体(PTFE、15μmの厚さ、80%孔隙率、0.45μmの気孔サイズ)をエタノールに30分間含浸した後、50℃で1時間の間真空乾燥して気孔内部の不純物を除去した後、ブタノールに常温で30分間含浸して前処理した。
ポリエチレン多孔性支持体(PE、15μmの厚さ、70%孔隙率、0.45μmの気孔サイズ)を用いた他には製造例3と同じ方法で前処理した。
表1に提示するように、製造例1及び2の電解質フィルムの電解質膜上にブタノール0.3mlを薄くスプレーした後、ロールプレス器を用いて80〜100℃で3barの圧力を加えて製造例3及び4の前処理された多孔性支持体の両面に製造例1及び2の電解質膜が形成された3層の強化複合膜を製造した。製造された強化複合膜は、70℃の温度で8時間の間溶媒を除去した後、20±5μmの厚さ(表2)の強化複合膜を取得した。
化式(1)の炭化水素系高分子であるポリフェニルスルホン高分子(イオン交換容量:1.50meq/g乾燥樹脂)をNMPで完全に溶解させて10濃度%(w/v)の電解質溶液を製造し、前記製造された電解質溶液はPET離型フィルム上にソリューションキャスティングした後、70℃のホットプレートで8時間の間溶媒を蒸発させてから120℃で4時間をさらに乾燥して離型フィルムを除去し、20±5μmの厚さの電解質膜を取得した。
化式(2)の過フッ素化界高分子であるナフィオン(イオン交換容量:0.9meq/g乾燥樹脂)をNMPで完全に溶解させて10濃度%(w/v)の電解質溶液を製造した。前記製造された電解質溶液は、PET離型フィルム上にソリューションキャスティングした後、70℃のホットプレートで8時間の間溶媒を蒸発させてから120℃で4時間をさらに乾燥した後に離型フィルムを除去し、20±5μmの厚さの電解質膜を取得した。
化式(2)の過フッ素化界高分子であるナフィオン懸濁液(デュポン社製、製品番号:DE2021)をNMPで置換して、10濃度%(w/v)の電解質溶液を製造し、ポリテトラフルオロエチレン多孔性支持体(PTFE、15umの厚さ、80%孔隙率、0.45umの気孔サイズ)上にソリューションキャスティングした後、70℃で減圧蒸発させて22±5μmの厚さの電解質膜を有する強化複合膜を取得した。
製造例2の電解質フィルムと前処理していないポリテトラフルオロエチレン多孔性支持体(PTFE、15umの厚さ、80%孔隙率、0.45umの気孔サイズ)を用いて実施形態3と同じ方法で20±5μmの厚さの電解質膜を有する強化複合膜を取得した。
実施形態1〜4及び比較例1〜4で製造された膜25℃で24時間超純水に浸した後、乾燥前後の重さ差に基づいて算出した。含水率(%)は数式(1)で算出された。
含水率測定法と同様に、実施形態1〜4及び比較例1〜4で製造された膜25℃で24時間超純水に浸した後、含浸前後の電解質膜の面積変化として算出した。寸法変化率(%)は、数式(2)で算出された。
実施形態1〜4及び比較例1〜4で製造された膜4cm、1cmの大きさに切った後、セルに取り付け、取り付けたセルを温度と湿度の調整ができるチャンバーで25℃の蒸留水に入れ、セルの各電極はインピーダンス測定装置と連結して水素イオンの伝導度を測定した。各区間で測定されたインピーダンス値は、下の数式(3)によってプロトン伝導度として算出された。
Claims (16)
- 多孔性支持体層と、
前記多孔性支持体層の一面又は両面上に形成された電解質膜層と、
を含む複合膜を含み、
前記多孔性支持体層の少なくとも一部に電解質が含浸された、強化複合膜。 - 前記多孔性支持体層は、1μm〜30μmの厚さを有し、
前記多孔性支持体層は、50%以上の孔隙率であり、0.3μm〜1μmの直径の気孔を含む、請求項1に記載の強化複合膜。 - 前記多孔性支持体は、ポリテトラフルオロエチレン(PTFE)、ポリエチレン(PE)、フッ化ポリビニリデン(PVdF)、ポリイミド(PI)、ポリプロピレン(PP)、セルロース、及びナイロンからなる群から選択された1種以上を含む、請求項1に記載の強化複合膜。
- 前記電解質は、過フッ素化系、スルホン化炭化水素系高分子又はこの2つを含む、請求項1に記載の強化複合膜。
- 前記強化複合膜は、前記電解質100重量部に対して0.5〜5重量部の添加剤をさらに含み、
前記添加剤は、遷移金属塩と、2、2’−ビピリジン、ハイドロキノン、ピラジン−2、3−カルボン酸、ピラジン−2、3−ジカルボン酸、2(−ナフタレン−2−イル)−1−(ナフタレン−7−イル)ヒドラジン及び4−(3−(ピリジン−4−イル)プロピル)ピリジンからなる群から選択される少なくともいずれか1つの有機化合物と、セリウム(III)トリフルオロメタンスルホン酸と、セリウム(III)トリフルオロアセチルアセトナートと、トリス(5−ヨウ素−L−プロリナト−N1、O2)−(9CI)セリウム(III)塩からなる群から選択される少なくともいずれか1つを含む、請求項1に記載の強化複合膜。 - 前記多孔性支持体層内の電解質含浸率は90%以上である、請求項1に記載の強化複合膜。
- 含浸されない電解質層の厚さは5μm以下である、請求項1に記載の強化複合膜。
- 前記強化複合膜は、高分子電解質膜、水電解用高分子電解質膜、レドックスフロー電池電解質膜、大容量エネルギー貯蔵装置電解質膜、塩分濃度差発電電解質膜、淡水用分離膜、気体分離用分離膜、又は、浄水処理用分離膜である、請求項1に記載の強化複合膜。
- 前記強化複合膜は、2つ以上の前記複合膜が積層された多重強化複合膜である、請求項1に記載の強化複合膜。
- 離型フィルム上に電解質膜を形成する電解質フィルムの製造ステップと、
多孔性支持体の一面又は両面に前記電解質フィルムを配置する配置ステップと、
複合膜を形成するように前記電解質フィルムの電解質膜を多孔性支持体の一面又は両面に転写する転写ステップと、
を含み、
前記転写ステップは、ロールプレス工程によって行われ、
前記転写ステップで前記多孔性支持体の少なくとも一部に電解質が含浸される、強化複合膜の製造方法。 - 前記電解質膜は、電解質及び極性溶媒を含む電解質溶液を用いて形成され、
前記電解質溶液において前記電解質は、5〜30%(w/v)の濃度で含まれる、請求項10に記載の強化複合膜の製造方法。 - 前記電解質フィルムの製造ステップ後に電解質フィルムの乾燥ステップをさらに含み、
前記乾燥ステップは、40℃〜80℃で溶媒を除去した後、90℃〜150℃で乾燥して3μm〜30μmの厚さの電解質膜を形成する、請求項10に記載の強化複合膜の製造方法。 - 前記配置ステップ前に、前記電解質フィルム上に極性溶媒を噴霧する電解質フィルムの前処理ステップをさらに含む、請求項10に記載の強化複合膜の製造方法。
- 前記配置ステップ前に、前記多孔性支持体を極性溶液に浸して含浸する多孔性支持体の前処理ステップをさらに含み、
前記多孔性支持体の前処理ステップは、常温ないし50℃の温度で30分〜5時間の間行われる、請求項10に記載の強化複合膜の製造方法。 - 前記転写ステップ後に複合膜の一面の離型フィルムを分離する分離ステップと、
前記離型フィルムが分離した電解質膜層が多孔性支持体の一面又は両面に接するように複合膜を配置する配置ステップと、
前記複合膜の電解質膜を多孔性支持体の一面又は両面に転写する転写ステップと、
をさらに含む、請求項10に記載の強化複合膜の製造方法。 - 前記転写ステップ後に複合膜の一面の離型フィルムを分離する分離ステップと、
前記離型フィルムが分離した電解質膜層及び電解質フィルムの電解質膜がそれぞれ多孔性支持体の一面に接するように複合膜及び電解質フィルムを配置する配置ステップと、
前記電解質膜を多孔性支持体の両面に転写する転写ステップと、
をさらに含む、請求項10に記載の強化複合膜の製造方法。
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