WO2006128106A2 - End-capped ion-conductive polymers - Google Patents

End-capped ion-conductive polymers Download PDF

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Publication number
WO2006128106A2
WO2006128106A2 PCT/US2006/020736 US2006020736W WO2006128106A2 WO 2006128106 A2 WO2006128106 A2 WO 2006128106A2 US 2006020736 W US2006020736 W US 2006020736W WO 2006128106 A2 WO2006128106 A2 WO 2006128106A2
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Prior art keywords
ion
conducting
polymer
copolymer
membrane
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PCT/US2006/020736
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French (fr)
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WO2006128106A3 (en
Inventor
Jian Ping Chen
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Polyfuel, Inc.
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Priority to EP06760509A priority Critical patent/EP1883671A2/en
Priority to JP2008513806A priority patent/JP2008542478A/en
Priority to CA002608098A priority patent/CA2608098A1/en
Publication of WO2006128106A2 publication Critical patent/WO2006128106A2/en
Publication of WO2006128106A3 publication Critical patent/WO2006128106A3/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
    • C08G65/48—Polymers modified by chemical after-treatment
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G61/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G61/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
    • C08G61/12—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/20—Manufacture of shaped structures of ion-exchange resins
    • C08J5/22—Films, membranes or diaphragms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/20—Manufacture of shaped structures of ion-exchange resins
    • C08J5/22—Films, membranes or diaphragms
    • C08J5/2287—After-treatment
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/06—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances
    • H01B1/12—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of other non-metallic substances organic substances
    • H01B1/122—Ionic conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1004—Fuel cells with solid electrolytes characterised by membrane-electrode assemblies [MEA]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/102—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer
    • H01M8/1023—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having only carbon, e.g. polyarylenes, polystyrenes or polybutadiene-styrenes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/102—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer
    • H01M8/1025—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having only carbon and oxygen, e.g. polyethers, sulfonated polyetheretherketones [S-PEEK], sulfonated polysaccharides, sulfonated celluloses or sulfonated polyesters
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/102—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer
    • H01M8/1027—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having carbon, oxygen and other atoms, e.g. sulfonated polyethersulfones [S-PES]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/102—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer
    • H01M8/1032—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having sulfur, e.g. sulfonated-polyethersulfones [S-PES]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/1039—Polymeric electrolyte materials halogenated, e.g. sulfonated polyvinylidene fluorides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1016—Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018—Polymeric electrolyte materials
    • H01M8/1041—Polymer electrolyte composites, mixtures or blends
    • H01M8/1044—Mixtures of polymers, of which at least one is ionically conductive
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2371/00—Characterised by the use of polyethers obtained by reactions forming an ether link in the main chain; Derivatives of such polymers
    • C08J2371/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08J2371/10—Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • C08J2371/12—Polyphenylene oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M2008/1095—Fuel cells with polymeric electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2250/00—Fuel cells for particular applications; Specific features of fuel cell system
    • H01M2250/20—Fuel cells in motive systems, e.g. vehicle, ship, plane
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0017—Non-aqueous electrolytes
    • H01M2300/0065—Solid electrolytes
    • H01M2300/0082—Organic polymers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/40—Application of hydrogen technology to transportation, e.g. using fuel cells

Definitions

  • This invention relates to end-capped ion-conductive polymers that are useful in forming polymer electrolyte membranes used in fuel cells.
  • Fuel cells are promising power sources for portable electronic devices, electric vehicles, and other applications due mainly to their non-polluting nature.
  • polymer electrolyte membrane based fuel cells such as direct methanol fuel cells (DMFCs) and hydrogen fuel cells, have attracted significant interest because of their high power density and energy conversion efficiency.
  • DMFCs direct methanol fuel cells
  • hydrogen fuel cells have attracted significant interest because of their high power density and energy conversion efficiency.
  • the "heart" of a polymer electrolyte membrane based fuel cell is the so called “membrane-electrode assembly” (MEA), which comprises a proton exchange membrane (PEM), catalyst disposed on the opposite surfaces of the PEM to form a catalyst coated membrane (CCM) and a pair of electrodes (i.e., an anode and a cathode) disposed to be in electrical contact with the catalyst layer.
  • MEA membrane-electrode assembly
  • PEM proton exchange membrane
  • CCM catalyst coated membrane
  • electrodes i.e., an anode and a cathode
  • Nafion® loses conductivity when the operation temperature of the fuel cell is over 8O 0 C. Moreover, Nafion® has a very high methanol crossover rate, which impedes its applications in DMFCs.
  • U.S. Patent No. 5,773,480 assigned to Ballard Power System, describes a partially fluorinated proton conducting membrane from a, ⁇ , /S-trifluorostyrene.
  • One disadvantage of this membrane is its high cost of manufacturing due to the complex synthetic processes for monomer a, ⁇ , and the poor sulfonation ability of poly (a, ⁇ , ⁇ -trifluorostyrene).
  • Another disadvantage of this membrane is that it is very brittle, thus has to be incorporated into a supporting matrix.
  • Ion conductive block copolymers are disclosed in PCT/US2003/015351.
  • ion-conducting polyarylene ketones and polyarylene sulfones can be synthesized from the condensation of difluoro or dichloro, and diol or dithiol monomers, in the presence of a base (i.e., K 2 CO 3 ) in a mixture of DMSO and toluene.
  • a polymer synthesized from difluoro, diol and dithiol monomers can have chemically reactive halogen, hydroxyl or thiol groups at each of the polymer chain ends or a halogen at one end and hydroxyl or thiol at the other.
  • Ion-conducting copolymers having terminal groups that are chemically reactive may be detrimental to the stability of the ion-conducting copolymer, especially when fabricated as a PEM that is used in a fuel cell.
  • the redox reactions that occur at or near the surface of the PEM, including the generation of free radicals, can result in chemical degradation of the PEM by reactions that occur with the chemically reactive end groups. This can decrease the performance and lifetime of the PEM.
  • At least one of the chemically reactive end groups of the ion-conducting copolymers are end-capped with a chemically inactive monomer or oligomer.
  • Such end-capping can improve not only polymer stability, but also offer better control of the molecular weight of the copolymer. End-capping can also narrow the molecular weight distribution, which can affect water uptake, methanol crossover for direct methanol fuel cells and oxidative stability for hydrogen fuel cells.
  • the end-capped ion-conducting copolymers are preferably made by combining the end-capping monomer with the monomers and/or oligomers that are polymerized to form the ion-conducting copolymer.
  • the end-capped ion-conductive copolymers can be used to fabricate polymer electrolyte membranes (PEM's), catalyst coated polymer electrolyte membranes (CCM's) and membrane electrode assemblies (MEA's) that find particular utility in hydrogen fuel cells and direct methanol fuel cells.
  • PEM's polymer electrolyte membranes
  • CCM's catalyst coated polymer electrolyte membranes
  • MEA's membrane electrode assemblies
  • Such fuel cells can be used in electronic devices, both portable and fixed, power supplies including auxiliary power units (APU' s) and as locomotive power for vehicles such as automobiles, aircraft and marine vessels and APU' s associated therewith.
  • FIG. 1 is a polarization curve for Membrane 6 which was made from the ion- conducting copolymer of Example 6.
  • FIG. 2 is a polarization curve for Membrane 9 which was made from the ion- conducting copolymer of Example 9.
  • the end-capped ion-conductive copolymers comprise one or more ion-conductive oligomers distributed in a polymeric backbone where the polymeric backbone contains at least one, two or three of the following: (1) one or more ion conductive monomers; (2) one or more non-ionic monomers; and (3) one or more non-ionic oligomers.
  • the ion conducting copolymers further comprise at least one end-capping monomer covalently linked to an end of the ion- conducting copolymer.
  • the ion-conducting oligomers, ion-conducting monomers, non-ionic monomers and/or non-ionic oligomers and end-capping monomers are covalently linked to each other by oxygen and/or sulfur.
  • the ion-conducting oligomers comprises first and second comonomers.
  • the first comonomer comprises one or more ion-conducting groups. At least one of the first or second comonomers comprises two leaving groups while the other comonomer comprises two displacement groups. In one embodiment, one of the first or second comonomers is in molar excess as compared to the other so that the oligomer formed by the reaction of the first and second comonomers contains either leaving groups or displacement groups at each end of the ion-conductive oligomer.
  • This precursor ion-conducting oligomer is combined with at least one of: (1) one or more precursor ion-conducting monomers; (2) one or more precursor non-ionic monomers; and (3) one or more precursor non-ionic oligomers (made from non-ionic monomers).
  • a precursor end-capping monomer is added to the reaction mixture to produce the end-capped ion-conducting polymer.
  • the precursor ion-conducting monomers, non-ionic monomers and/or non-ionic oligomers each contain two leaving groups or two displacement groups while the end-capping monomer (“monovalent monomer") contains one leaving group or one displacement group.
  • the choice of leaving group or displacement group for each of the precursors is chosen so that the precursors combine to form an oxygen and/or sulfur linkage.
  • the ion-conducting oligomer is not a part of the end-capped ion conductive polymer.
  • two or more of the (1) ion conductive monomer; (2) non-ionic monomer; and/or (3) non-ionic oligomers are present in the ion-conducting polymer.
  • a random copolymer is formed by appropriate choice of monomers and leaving and displacement groups.
  • LG leaving group
  • Leaving groups are well recognized in the art and include, for example, halides (chloride, fluoride, iodide, bromide), tosyl, mesyl, etc.
  • the monomer has at least two leaving groups.
  • the leaving groups may be "para" to each other with respect to the aromatic monomer to which they are attached. However, the leaving groups may also be ortho or meta.
  • displacing group is intended to include those functional moieties that can act typically as nucleophiles, thereby displacing a leaving group from a suitable monomer.
  • the monomer with the displacing group is attached, generally covalently, to the monomer that contained the leaving group.
  • fluoride groups from aromatic monomers are displaced by phenoxide, alkoxide or sulfide ions associated with an aromatic monomer.
  • the displacement groups are preferably para to each other.
  • the displacing groups may be ortho or meta as well.
  • End-capping monomers usually have monovalent displacement groups or leaving groups that react with the leaving or replacement groups respectively in the nascent polymer, i.e., they react during the polymerization of the components that form the ion-conducting polymer.
  • Table 1 sets forth combinations of exemplary leaving groups and displacement groups that can be used to make ion-conducting polymers that can be end-capped.
  • the precursor ion-conducting oligomer contains two leaving groups (e.g. fluorine (F)) while the other three components contain leaving groups and/or displacement groups (e.g. hydroxyl (-OH)). Sulfur linkages can be formed by replacing -OH with thiol (- SH).
  • the leaving group F on the ion conducing oligomer can be replaced with a displacement group in which case the other precursors are modified to substitute leaving groups for displacement groups and/or to substitute displacement groups for leaving groups.
  • the preferred combination of precursor non-ionic oligomers, precursor ion-conducting monomers and precursor non-ionic monomers is set forth in lines 2-7 of Table 1. Other combinations of the different components are apparent.
  • the relative amounts of precursors can be chosen so that two leaving groups or displacement groups are present at the end of the polymer so that both ends can be capped if sufficient end capping monomer or oligomer are present.
  • the relative amounts of precursors can be chosen so that the polymer has one leaving group at one end and one displacement group at the other end so that one terminus is end capped with a monomer or oligomer that contains a leaving group or a displacement group.
  • the ion-conductive copolymer may be represented by Formula I:
  • Ar 1 , Ar 2 , A ⁇ 3 and Ar 4 are independently the same or different aromatic moieties, at least one of ArI comprises an ion-conducting group; at least one of Ar 2 comprises an ion-conducting group;
  • T, U, V and W are linking moieties
  • X are independently -O- or -S-;
  • i and j are independently integers greater than 1;
  • a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least one of b, c and d are greater than 0; and
  • m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
  • Ri and R 2 are end-capping monomers and/or oligomers where at least one of Ri and R 2 is present in said copolymer.
  • the ion-conducting copolymer may also be represented by Formula II;
  • Ari, Ar 2 , Ar 3 and Ar 4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile;
  • At least one of ArI comprises an ion-conducting group
  • At least one of Ar2 comprises an ion-conducting group; [0045] T, U, V and W are independently a bond, -C(O)-,
  • X are independently -O- or -S-;
  • i and j are independently integers greater than 1 ;
  • a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least one of b, c and d are greater than 0; and
  • n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
  • Ri and R 2 are end-capping monomers and/or oligomers where at least one of the Ri and R 2 is present in said copolymer.
  • the ion-conductive copolymer can also be represented by Formula III: [0052]
  • Ar 1 , Ar 2 , Ar 3 and Ar 4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile;
  • At least one of ArI comprises an ion-conducting group
  • At least one of Ar2 comprises an ion-conducting group
  • T 5 U 5 V and W are independently a bond O, S 5 C(O), S(O 2 ), alkyl, branched alkyl, fluoroalkyl, branched fluoroalkyl, cycloalkyl, aryl, substituted aryl or heterocycle;
  • [oo57i X are independently -O- or -S-;
  • i and j are independently integers greater than 1;
  • a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least two of b, c and d are greater than 0; and
  • m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
  • Ri and R 2 are end-capping monomers and/or oligomers where at least one of the Ri and R 2 is present in said copolymer.
  • these formulas are directed to ion-conducting polymers that include ion-conducting oligomer(s) in combination at least two of the following: (1) one or more ion conductive monomers, (2) one or more non-ionic monomers and (3) one or more non- ionic oligomers.
  • these formulas are directed to ion-conducting polymers that include at least two of the following: (1) one or more ion conductive monomers, (2) one or more non-ionic monomers and (3) one or more non-ionic oligomers. Preferred combinations are of (1 and 2) and (1 and 3).
  • i and j are independently from 2 to 12, more preferably from 3 to 8 and most preferably from 4 to 6.
  • the mole fraction "a" of ion-conducting oligomer in the copolymer is zero or greater than zero e.g. between 0.3 and 0.9, more preferably from 0.3 to 0.7 and most preferably from 0.3 to 0.5.
  • the mole fraction "b" of ion-conducting monomer in the copolymer is preferably from 0 to 0.5, more preferably from 0.1 to 0.4 and most preferably from 0.1 to 0.3.
  • the mole fraction of "c" of non-ionic oligomer is preferably from 0 to 0.3, more preferably from 0.1 to 0.25 and most preferably from 0,01 to 0.15.
  • the mole fraction "d" of non-ionic monomer is preferably from 0 to 0.7, more preferably from 0.2 to 0.5 and most preferably from 0.2 to 0.4.
  • b, c and d are all greater then zero. In other cases, a and c are greater than zero and b and d are zero. In other cases, a is zero, b is greater than zero and at least c or d or c and d are greater than zero. Nitrogen is generally not present in the copolymer backbone.
  • indices m, n, o, and p are integers that take into account the use of different monomers and/or oligomers in the same copolymer or among a mixture of copolymers, where m is preferably 1, 2 or 3, n is preferably 1 or 2, o is preferably 1 or 2 and p is preferably 1, 2, 3 or 4.
  • At least two of Ar 2 , Ar 3 and Ar 4 are different from, each other.
  • Ax 2 , Ar 3 and Ar 4 are each different from the other.
  • the precursor ion conductive monomer used to make the ion-conducting polymer is not 2,2' disulfonated 4,4' dihydroxy biphenyl; (2) the ion conductive polymer does not contain the ion-conducting monomer that is formed using this precursor ion conductive monomer; and/or (3) the ion-conducting polymer is not the polymer made according to Example 3 herein.
  • a and c are zero and b and d are greater than zero in Formulas I, II and III.
  • random copolymers are generally made by use of at least three different precursor monomers where at least one is an ion conducting monomer and at least one of the precursor monomers contains a monomer with two leaving groups and at least one of the other two is a monomer with two displacement groups.
  • Formula IV is an example of a preferred end capped random coplolymer where n and m are mole fractions where n is between 0.5 and 0.9 and m is between 0.1 and 0.5. A preferred ratio is where n is 0.7 and m is 0.3.
  • Table 2 discloses some of the monomers used to make ion-conductive copolymers.
  • the bifunctional precursor monomers and/or oligomers used to make the ion- conducting copolymer can be used as an end-capping monomer or oligomer by removal of one of the leaving or displacement groups.
  • the precursors of Rl and R2 can be: (1) a monovalent ion-conducting oligomer represented by the formulas (Y)-[-(Ar I -T-)i-Ar I ]and [(Ar r T-)i-Ari-]-(Y); ; (2) an ion-conducting monomer represented by the formulas (Y)-C-Ar 2 -U-Ar 2 ) and (Ar 2 -U- Ar 2 -)-(Y); (3) a non-ionic oligomer represented by the formula (Y)-[(-Ar 3 -V-) j -Ar 3 ]and [(Ar 3 - V-) j - Ar 3 -] -(Y) and
  • non-ionic monovalent precursor monomers can be used:
  • the monovalent monomer or oligomer can further comprise an ion-conducting group such as sulfonic, phosphonic or carboxylic acids.
  • the ion conductive copolymers that can be end-capped include the random copolymers disclosed in US Patent Application No. 10/438,186, filed May 13, 2003, entitled “Sulfonated Copolymer,” Publication No. US 2004-0039148 Al, published February 26, 2004, and US Patent Application No. 10/987,178, filed November 12, 2004, entitled “Ion Conductive Random Copolymer” and the block copolymers disclosed in US Patent Application No. 10/438,299, filed May 13, 2003, entitled “Ion Conductive Block Copolymers,” published July 1, 2004, Publication No. 2004- 0126666.
  • Other ion conductive copolymers include the oligomeric ion conducting polymers disclosed in US Patent Application No.
  • the non-conductive polymer may be a copolymer having the same backbone as these copolymers without the ion conductive groups.
  • ion- conducting copolymers that can be end-capped are made for comonomers such as those used to make sulfonated trifluorostyrenes (U.S. Patent No. 5,773,480), acid-base polymers, (U.S. Patent No. 6,300,381), poly arylene ether sulfones (U.S. Patent Publication No. US2002/0091225A1); graft polystyrene (Macromolecules 35:1348 (2002)); polyimides (U.S. Patent No. 6,586,561 and J. Membr. Sd. 160:127 (1999)) and Japanese Patent Applications Nos. JP2003147076 and JP2003055457, each of which are expressly identified herein by reference.
  • comonomers such as those used to make sulfonated trifluorostyrenes (U.S. Patent No. 5,773,480), acid-base polymers, (U.S. Patent No. 6,300,381), poly ary
  • the ionic and non-ionic monomers or oligomers need not be arylene but rather may be aliphatic or perfluorinated aliphatic backbones containing ion-conducting groups.
  • Ion-conducting groups may be attached to the backbone or maybe pendant to the backbone, e.g., attached to the polymer backbone via a linker.
  • ion- conducting groups can be formed as part of the standard backbone of the polymer. See, e.g., U.S. 2002/018737781, published December 12, 2002 incorporated herein by reference. Any of these ion-conducting oligomers can be used to practice the present invention.
  • the mole percent of ion-conducting groups when only one ion-conducting group is present is preferably between 30 and 70%, or more preferably between 40 and 60%, and most preferably between 45 and 55%.
  • the preferred sulfonation is 60 to 140%, more preferably 80 to 120% , and most preferably 90 to 110%.
  • the amount of ion-conducting group can be measured by the ion exchange capacity (IEC).
  • National® typically has a ion exchange capacity of 0.9 meq per gram.
  • the IEC be between 0.9 and 3.0 meq per gram, more preferably between 1.0 and 2.5 meq per gram, and most preferably between 1.6 and 2.2 meq per gram.
  • end capping can be applied to many other systems.
  • the ionic oligomers, non-ionic oligomers as well as the ionic and non-ionic monomers need not be arylene but rather may be aliphatic or perfluorinated aliphatic backbones containing ion-conducting groups.
  • Ion-conducting groups may be attached to the backbone or may be pendant to the backbone, e.g., attached to the polymer backbone via a linker.
  • ion-conducting groups can be formed as part of the standard backbone of the polymer.
  • Polymer membranes may be fabricated by solution casting of the ion- conductive copolymer. When cast into a membrane for use in a fuel cell, it is preferred that the membrane thickness be between 0.1 to 10 mils, more preferably between 1 and 6 mils, most preferably between 1.5 and 2.5 mils.
  • a membrane is permeable to protons if the proton flux is greater than approximately 0.005 S/cm, more preferably greater than 0.01 S/cm, most preferably greater than 0.02 S/cm.
  • a membrane is substantially impermeable to methanol if the methanol transport across a membrane having a given thickness is less than the transfer of methanol across a Nafion membrane of the same thickness.
  • the permeability of methanol is preferably 50% less than that of a Nafion membrane, more preferably 75% less and most preferably greater than 80% less as compared to the Nafion membrane.
  • a CCM comprises a PEM when at least one side and preferably both of the opposing sides of the PEM are partially or completely coated with catalyst.
  • the catalyst is preferable a layer made of catalyst and ionomer.
  • Preferred catalysts are Pt and Pt-Ru.
  • Preferred ionomers include Nafion and other ion-conductive polymers.
  • anode and cathode catalysts are applied onto the membrane using well established standard techniques.
  • platinum/ruthenium catalyst is typically used on the anode side while platinum catalyst is applied on the cathode side.
  • platinum or platinum/ruthenium is generally applied on the anode side, and platinum is applied on the cathode side.
  • Catalysts may be optionally supported on carbon.
  • the catalyst is initially dispersed in a small amount of water (about lOOmg of catalyst in 1 g of water). To this dispersion a 5% ionomer solution in water/alcohol is added (0.25-0.75 g). The resulting dispersion may be directly painted onto the polymer membrane.
  • isopropanol (1-3 g) is added and the dispersion is directly sprayed onto the membrane.
  • the catalyst may also be applied onto the membrane by decal transfer, as described in the open literature ⁇ Electrochimica Acta, 40: 297 (1995)).
  • an MEA refers to an ion- conducting polymer membrane made from a CCM according to the invention in combination with anode and cathode electrodes positioned to be in electrical contact with the catalyst layer of the CCM.
  • the electrodes are in electrical contact with the catalyst layer, either directly or indirectly via a gas diffusion or other conductive layer, so that they are capable of completing an electrical circuit which includes the CCM and a load to which the fuel cell current is supplied.
  • a first catalyst is electrocatalytically associated with the anode side of the PEM so as to facilitate the oxidation of hydrogen or organic fuel.
  • Such oxidation generally results in the formation of protons, electrons and, in the case of organic fuels, carbon dioxide and water. Since the membrane is substantially impermeable to molecular hydrogen and organic fuels such as methanol, as well as carbon dioxide, such components remain on the anodic side of the membrane.
  • Electrons formed from the electrocatalytic reaction are transmitted from the anode to the load and then to the cathode. Balancing this direct electron current is the transfer of an equivalent number of protons across the membrane to the cathodic compartment. There an electrocatalytic reduction of oxygen in the presence of the transmitted protons occurs to form water.
  • air is the source of oxygen. In another embodiment, oxygen-enriched air or oxygen is used.
  • the membrane electrode assembly is generally used to divide a fuel cell into anodic and cathodic compartments.
  • a fuel such as hydrogen gas or an organic fuel such as methanol is added to the anodic compartment while an oxidant such as oxygen or ambient air is allowed to enter the cathodic compartment.
  • a number of cells can be combined to achieve appropriate voltage and power output.
  • Such applications include electrical power sources for residential, industrial, commercial power systems and for use in locomotive power such as in automobiles.
  • fuel cells in portable electronic devices such as cell phones and other telecommunication devices, video and audio consumer electronics equipment, computer laptops, computer notebooks, personal digital assistants and other computing devices, GPS devices and the like.
  • the fuel cells may be stacked to increase voltage and current capacity for use in high power applications such as industrial and residential sewer services or used to provide locomotion to vehicles.
  • Such fuel cell structures include those disclosed in U.S. Patent Nos.
  • Such CCM and MEM's are generally useful in fuel cells such as those disclosed in U.S. Patent Nos. 5,945,231, 5,773,162, 5,992,008, 5,723,229, 6,057,051, 5,976,725, 5,789,093, 4,612,261, 4,407,905, 4,629,664, 4,562,123, 4,789,917, 4,446,210, 4,390,603, 6,110,613, 6,020,083, 5,480,735, 4,851,377, 4,420,544, 5,759,712, 5,807,412, 5,670,266, 5,916,699, 5,693,434, 5,688,613, 5,688,614, each of which is expressly incorporated herein by reference.
  • the CCM's and MEA's of the invention may also be used in hydrogen fuel cells that are known in the art.
  • Examples include 6,630,259; 6,617,066; 6,602,920; 6,602,627; 6,568,633; 6,544,679; 6,536,551; 6,506,510; 6,497,974, 6,321,145; 6,195,999; 5,984,235; 5,759,712; 5,509,942; and 5,458,989 each of which are expressly incorporated herein by reference.
  • the ion-conducting polymer membranes of the invention also find use as separators in batteries.
  • Particularly preferred batteries are lithium ion batteries.
  • the molar % of the mono-fluorinated monomer used to end-cap the random copolymer BisZ was adjusted to 1 mol%, 2 mol%, and 5 mol% for F-K, and 1 mol% both for F-B and F-CN, to ensure that OH end groups can be fully end-capped.
  • the reaction mixture was slowly stirred under a slow nitrogen stream. After heating at ⁇ 85 0 C for 1 h and at ⁇ 120°C for 1.5 h, the reaction temperature was raised to 140 0 C for 1.5 h, and at 155 0 C for 1 h, finally to 170 0 C for 2 h. After cooling to 70 0 C with continuing stirring, the solution was dropped into 2 L of cooled methanol with a vigorous stirring. The precipitates were filtrated and washed with Di-water four times and dried at 80 0 C for one day. The sodium form polymer was exchanged to acid form by washing the polymer in hot sulfuric acid solution (1.5 M) twice (1 h each) and in cold di-water twice. The polymer was then dried at 80 0 C overnight and at 80 0 C under vacuum for additional day. This polymer has an inherent viscosity of 1.20 dl/g in DMAc (0.25 g/dl).
  • This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g 5 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzo ⁇ hone (SBisK, 15.84 g, 0.0375 mol), 1,1- bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobenzophenone (F-K, 0.50 g, 0.0025 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 niL of DMSO and 112 mL of Toluene.
  • This polymer after acid treatment has an inherent viscosity of 0.90 dl/g in DMAc (0.25 g/dl).
  • This polymer was synthesized in a similar way as described in comparative 1 , using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzo ⁇ henone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobiphenyl (0.215 g, 0.00125 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene.
  • This polymer after acid treatment has an inherent viscosity of 1.18 dl/g in DMAc (0.25 g/dl).
  • Table 3 summarizes data on polymer 1-5 made according to Examples 1-5. With introduction of 1 mol% end-capping monomers, the polymers synthesized have good molecular weights. As expected, the polymer end-capped with 5 mol% F-K has a very low molecular weight due to the unbalanced stoichiometry. A close look on the Z-K series reveals that these polymers have good polydispersities ( ⁇ 2.3), whereas the non-encapped comparative example 1 has a PDI of 2.8.
  • Polymer 2 1.05./1.02 1.14 4.31/9.36/19.21/2.17 4.30/8.76/17.69/2.04
  • MEA 1 from membrane 1 has a power density at 138 mW/cm2 at 0.4 V, and methanol crossover of 46 mA/cm2, whereas comparative membrane 1 has a power at 124 mW/cm2 and a crossover of 53 mA/cm2.
  • Membrane LV IEC Water Swelling Conductivity Polymer Polymer Uptake (%) 60C/Boiled (%) (S/cm) Membrane 6 1.64 2.15 58 53 0.118/0.122
  • Membrane 7 1.00 1.93 166 130 0.098/0.075
  • This oligomer was synthesized in a similar way as described in oligomer 1, using following compositions: bis(4-fluorophenyl) sulfone (63.56 g, 0.25 mol), 4,4'- dihydroxytetraphenylmethane (66.08 g, 0.1875 mol), and anhydrous potassium carbonate (33.67 g, 0.325 mol), 450 mL of DMSO and 225 mL of Toluene.
  • This polymer was synthesized in a similar way as described in comparative 2, using following compositions: 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 22.30 g), Oligomer 1 (16.85 g), 4,4'-(hexafluoroisopro ⁇ ylidene)diphenol (20.37 g), 4-fluorobiphenyl (0.227 g), and anhydrous potassium carbonate (10.83 g), were added together with a mixture of anhydrous DMSO (228 mL) and freshly distilled toluene (114 mL). This polymer after acid treatment has an inherent viscosity of 1.00 dl/g in DMAc (0.25 g/dl).
  • This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (32.70 g), 4-t-butylphenol (0.469 g), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene.
  • BisK 4,4'-difluorobenzophenone
  • SBisK 3,3'-disulfonated-4,4'-difluorobenzophenone
  • l,l-bis(4-hydroxyphenyl)cyclohexane 32.70 g
  • 4-t-butylphenol
  • This polymer after acid treatment has an inherent viscosity of 1.26 dl/g in DMAc (0.25 g/dl). Its membrane swelling is 19.5%, water uptake is 21%, conductivity is 0.018 S/cm at 60 C and 0.031 S/cm after boiled, respectively.

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Abstract

The invention provides end-capped ion-conductive copolymers that can be used to fabricate proton exchange membranes (PEM's), catalyst coated proton exchange membranes (CCM's) and membrane electrode assemblies (MEA's) that are useful in fuel cells and their application in electronic devices, power sources and vehicles.

Description

END-CAPPED ION-CONDUCTIVE POLYMERS
FIELD OF THE INVENTION
[ooi] This invention relates to end-capped ion-conductive polymers that are useful in forming polymer electrolyte membranes used in fuel cells.
CROSS-REFERENCE TO RELATED APPLICATIONS
[002] The present application claims priority to U.S. Provisional Application No. 60/685,300 filed May 27, 2005 which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[003] Fuel cells are promising power sources for portable electronic devices, electric vehicles, and other applications due mainly to their non-polluting nature. Of various fuel cell systems, polymer electrolyte membrane based fuel cells such as direct methanol fuel cells (DMFCs) and hydrogen fuel cells, have attracted significant interest because of their high power density and energy conversion efficiency. The "heart" of a polymer electrolyte membrane based fuel cell is the so called "membrane-electrode assembly" (MEA), which comprises a proton exchange membrane (PEM), catalyst disposed on the opposite surfaces of the PEM to form a catalyst coated membrane (CCM) and a pair of electrodes (i.e., an anode and a cathode) disposed to be in electrical contact with the catalyst layer. [0041 Proton-conducting membranes for DMFCs are known, such, as Nafion® from the E.I. Dupont De Nemours and Company or analogous products from Dow Chemical. These perfluorinated hydrocarbon sulfonate ionomer products, however, have serious limitations when used in high temperature fuel cell applications. Nafion® loses conductivity when the operation temperature of the fuel cell is over 8O0C. Moreover, Nafion® has a very high methanol crossover rate, which impedes its applications in DMFCs.
[005) U.S. Patent No. 5,773,480, assigned to Ballard Power System, describes a partially fluorinated proton conducting membrane from a, β, /S-trifluorostyrene. One disadvantage of this membrane is its high cost of manufacturing due to the complex synthetic processes for monomer a, β,
Figure imgf000003_0001
and the poor sulfonation ability of poly (a, β, β-trifluorostyrene). Another disadvantage of this membrane is that it is very brittle, thus has to be incorporated into a supporting matrix.
[006] U.S. Patent Nos. 6,300,381 and 6,194,474 to Kerrres, et al. describe an acid- base binary polymer blend system for proton conducting membranes, wherein the sulfonated poly(ether sulfone) was made by post-sulfonation of the poly (ether sulfone).
[007] M. Ueda in the Journal of Polymer Science, 31(1993): 853, discloses the use of sulfonated monomers to prepare the sulfonated poly(ether sulfone polymers).
loos] U.S. Patent Application US 2002/0091225 Al to McGrath, et al. used this method to prepare sulfonated polysulfone polymers.
[009] Ion conductive block copolymers are disclosed in PCT/US2003/015351.
[ooioi End-capping of poly (ether sulfones) is described in Muggli, et al., Journal of Polymer Science, 41 -.2850-2860 (2003).
[ooii] End-capping of sulfonated poly (ether sulfones) is described in Wang F. et al., Polymer Preprint, 43 492 (2002). [0012] Ion-conducting polymers with identical backbone structures can contain different end groups depending on the stoichiometry of the polymerization reaction. Such ion-conducting copolymers may differ in physical, mechanical, and chemical properties. For example, ion-conducting polyarylene ketones and polyarylene sulfones can be synthesized from the condensation of difluoro or dichloro, and diol or dithiol monomers, in the presence of a base (i.e., K2CO3) in a mixture of DMSO and toluene. Based on the stoichiometry, a polymer synthesized from difluoro, diol and dithiol monomers can have chemically reactive halogen, hydroxyl or thiol groups at each of the polymer chain ends or a halogen at one end and hydroxyl or thiol at the other.
SUMMARY OF THE INVENTION
[ooi3] Ion-conducting copolymers having terminal groups that are chemically reactive may be detrimental to the stability of the ion-conducting copolymer, especially when fabricated as a PEM that is used in a fuel cell. The redox reactions that occur at or near the surface of the PEM, including the generation of free radicals, can result in chemical degradation of the PEM by reactions that occur with the chemically reactive end groups. This can decrease the performance and lifetime of the PEM.
[ooi4] To minimize this problem, at least one of the chemically reactive end groups of the ion-conducting copolymers are end-capped with a chemically inactive monomer or oligomer. Such end-capping can improve not only polymer stability, but also offer better control of the molecular weight of the copolymer. End-capping can also narrow the molecular weight distribution, which can affect water uptake, methanol crossover for direct methanol fuel cells and oxidative stability for hydrogen fuel cells.
tools] The end-capped ion-conducting copolymers are preferably made by combining the end-capping monomer with the monomers and/or oligomers that are polymerized to form the ion-conducting copolymer. [0016] The end-capped ion-conductive copolymers can be used to fabricate polymer electrolyte membranes (PEM's), catalyst coated polymer electrolyte membranes (CCM's) and membrane electrode assemblies (MEA's) that find particular utility in hydrogen fuel cells and direct methanol fuel cells. Such fuel cells can be used in electronic devices, both portable and fixed, power supplies including auxiliary power units (APU' s) and as locomotive power for vehicles such as automobiles, aircraft and marine vessels and APU' s associated therewith.
BRIEF DESCRIPTION OF DRAWINGS
[00171 FIG. 1 is a polarization curve for Membrane 6 which was made from the ion- conducting copolymer of Example 6.
[ooi8] FIG. 2 is a polarization curve for Membrane 9 which was made from the ion- conducting copolymer of Example 9.
DETAILED DESCRIPTION OF THE INVENTION
[ooi9] In one aspect, the end-capped ion-conductive copolymers comprise one or more ion-conductive oligomers distributed in a polymeric backbone where the polymeric backbone contains at least one, two or three of the following: (1) one or more ion conductive monomers; (2) one or more non-ionic monomers; and (3) one or more non-ionic oligomers. In addition, the ion conducting copolymers further comprise at least one end-capping monomer covalently linked to an end of the ion- conducting copolymer. The ion-conducting oligomers, ion-conducting monomers, non-ionic monomers and/or non-ionic oligomers and end-capping monomers are covalently linked to each other by oxygen and/or sulfur.
[002Oi The ion-conducting oligomers comprises first and second comonomers. The first comonomer comprises one or more ion-conducting groups. At least one of the first or second comonomers comprises two leaving groups while the other comonomer comprises two displacement groups. In one embodiment, one of the first or second comonomers is in molar excess as compared to the other so that the oligomer formed by the reaction of the first and second comonomers contains either leaving groups or displacement groups at each end of the ion-conductive oligomer. This precursor ion-conducting oligomer is combined with at least one of: (1) one or more precursor ion-conducting monomers; (2) one or more precursor non-ionic monomers; and (3) one or more precursor non-ionic oligomers (made from non-ionic monomers). A precursor end-capping monomer is added to the reaction mixture to produce the end-capped ion-conducting polymer. The precursor ion-conducting monomers, non-ionic monomers and/or non-ionic oligomers each contain two leaving groups or two displacement groups while the end-capping monomer ("monovalent monomer") contains one leaving group or one displacement group. The choice of leaving group or displacement group for each of the precursors is chosen so that the precursors combine to form an oxygen and/or sulfur linkage.
[0021] Alternatively, the ion-conducting oligomer is not a part of the end-capped ion conductive polymer. In this situation, two or more of the (1) ion conductive monomer; (2) non-ionic monomer; and/or (3) non-ionic oligomers are present in the ion-conducting polymer. When only ion-conducting and non-ionic monomers are present, a random copolymer is formed by appropriate choice of monomers and leaving and displacement groups.
[0022] The term "leaving group" (LG) is intended to include those functional moieties that can be displaced by a nucleophilic moiety found, typically, in another monomer. Leaving groups are well recognized in the art and include, for example, halides (chloride, fluoride, iodide, bromide), tosyl, mesyl, etc. In certain embodiments, the monomer has at least two leaving groups. In the preferred polyphenylene embodiments, the leaving groups may be "para" to each other with respect to the aromatic monomer to which they are attached. However, the leaving groups may also be ortho or meta.
[00231 The term "displacing group" (DG) is intended to include those functional moieties that can act typically as nucleophiles, thereby displacing a leaving group from a suitable monomer. The monomer with the displacing group is attached, generally covalently, to the monomer that contained the leaving group. In a preferred polyarylene example, fluoride groups from aromatic monomers are displaced by phenoxide, alkoxide or sulfide ions associated with an aromatic monomer. In polyphenylene embodiments, the displacement groups are preferably para to each other. However, the displacing groups may be ortho or meta as well.
[0024] End-capping monomers usually have monovalent displacement groups or leaving groups that react with the leaving or replacement groups respectively in the nascent polymer, i.e., they react during the polymerization of the components that form the ion-conducting polymer.
[0025] Table 1 sets forth combinations of exemplary leaving groups and displacement groups that can be used to make ion-conducting polymers that can be end-capped. The precursor ion-conducting oligomer contains two leaving groups (e.g. fluorine (F)) while the other three components contain leaving groups and/or displacement groups (e.g. hydroxyl (-OH)). Sulfur linkages can be formed by replacing -OH with thiol (- SH). The leaving group F on the ion conducing oligomer can be replaced with a displacement group in which case the other precursors are modified to substitute leaving groups for displacement groups and/or to substitute displacement groups for leaving groups.
[0026] Table 1. Exemplary Leaving Groups (Fluorine) and Displacement Group (OH) Combinations
Figure imgf000008_0001
[0027] Preferred combinations of precursors for ion conducting polymers are set forth in lines 5 and 6 of Table 1.
[0028] When the ion-conducting oligomer is not present, the preferred combination of precursor non-ionic oligomers, precursor ion-conducting monomers and precursor non-ionic monomers is set forth in lines 2-7 of Table 1. Other combinations of the different components are apparent.
[0029] The relative amounts of precursors can be chosen so that two leaving groups or displacement groups are present at the end of the polymer so that both ends can be capped if sufficient end capping monomer or oligomer are present. Alternatively, the relative amounts of precursors can be chosen so that the polymer has one leaving group at one end and one displacement group at the other end so that one terminus is end capped with a monomer or oligomer that contains a leaving group or a displacement group.
[0030] The ion-conductive copolymer may be represented by Formula I:
[0031] Formula I
Rr[-(ArrT-)i-ArrX-] * / (-Ar2-U-Ar2-X-) £ / [-(Ar3-V-VAr3-X-] ; / (-Ar4-W-Ar4-X-) ^ /]-R2 [0032] wherein Ar1 , Ar2, Aτ3 and Ar4 are independently the same or different aromatic moieties, at least one of ArI comprises an ion-conducting group; at least one of Ar2 comprises an ion-conducting group;
[0033] T, U, V and W are linking moieties;
[0034] X are independently -O- or -S-;
[0035] i and j are independently integers greater than 1;
[0036] a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least one of b, c and d are greater than 0; and
[0037] m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
[0038] Ri and R2 are end-capping monomers and/or oligomers where at least one of Ri and R2 is present in said copolymer.
[0039] The preferred values of a, b, c, and d, i and j as well as m, n, o, and p are set forth below.
[0040] The ion-conducting copolymer may also be represented by Formula II;
[0041] Formula II
R1-[HAr ,-T-V-Ar1-X-] * / (-Ar2-U-Ar2-X-);' / [-(Ar3-V-VAr3-X-] : / (-Ar4-W-Ax4-X-) > Z]-R2
[0042) wherein Ari, Ar2, Ar3 and Ar4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile;
100431 at least one of ArI comprises an ion-conducting group;
[0044| at least one of Ar2 comprises an ion-conducting group; [0045] T, U, V and W are independently a bond, -C(O)-,
Figure imgf000010_0001
[0046] X are independently -O- or -S-;
[0047] i and j are independently integers greater than 1 ; and
[0048] a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least one of b, c and d are greater than 0; and
100491 m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
[ooso] Ri and R2 are end-capping monomers and/or oligomers where at least one of the Ri and R2 is present in said copolymer.
[oo5i| The ion-conductive copolymer can also be represented by Formula III: [0052] Formula III
R1-[KAr1-T-Oi-Ar1-X-] * / (-Ar2-U-Ar2-X-) \ / [-(Ar3-V-VAr3-X-J : / (-Ar4-W-Ar4-X-) J /J-R2
[00531 wherein Ar1 , Ar2, Ar3 and Ar4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile;
[0054] at least one of ArI comprises an ion-conducting group;
[0055] at least one of Ar2 comprises an ion-conducting group;
[0056] at least one where T5U5V and W are independently a bond O, S5 C(O), S(O2), alkyl, branched alkyl, fluoroalkyl, branched fluoroalkyl, cycloalkyl, aryl, substituted aryl or heterocycle;
[oo57i X are independently -O- or -S-;
[0058] i and j are independently integers greater than 1;
[00591 a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is 0 or greater than 0 and at least two of b, c and d are greater than 0; and
[0060] m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer.
[0061] Ri and R2 are end-capping monomers and/or oligomers where at least one of the Ri and R2 is present in said copolymer.
[0062] In each of the forgoing formulas I, II and III [-(ArrT-)i-Arr] "' is an ion- conducting oligomer; (-Ar2-U-Ar2-) \ is an ion-conducting monomer; [(- Ar3-V-^-Ar3- ] ° is a non-ionic oligomer; and (-Ar4- W-Ar4-)d p is a non-ionic monomer. Accordingly, these formulas are directed to ion-conducting polymers that include ion-conducting oligomer(s) in combination at least two of the following: (1) one or more ion conductive monomers, (2) one or more non-ionic monomers and (3) one or more non- ionic oligomers.
[0063] When the ion conducting oligomer is not present, these formulas are directed to ion-conducting polymers that include at least two of the following: (1) one or more ion conductive monomers, (2) one or more non-ionic monomers and (3) one or more non-ionic oligomers. Preferred combinations are of (1 and 2) and (1 and 3).
[0064] In preferred embodiments, i and j are independently from 2 to 12, more preferably from 3 to 8 and most preferably from 4 to 6.
[0065] The mole fraction "a" of ion-conducting oligomer in the copolymer is zero or greater than zero e.g. between 0.3 and 0.9, more preferably from 0.3 to 0.7 and most preferably from 0.3 to 0.5.
[0066] The mole fraction "b" of ion-conducting monomer in the copolymer is preferably from 0 to 0.5, more preferably from 0.1 to 0.4 and most preferably from 0.1 to 0.3.
[0067) The mole fraction of "c" of non-ionic oligomer is preferably from 0 to 0.3, more preferably from 0.1 to 0.25 and most preferably from 0,01 to 0.15.
[0068) The mole fraction "d" of non-ionic monomer is preferably from 0 to 0.7, more preferably from 0.2 to 0.5 and most preferably from 0.2 to 0.4.
[0069] In some instance, b, c and d are all greater then zero. In other cases, a and c are greater than zero and b and d are zero. In other cases, a is zero, b is greater than zero and at least c or d or c and d are greater than zero. Nitrogen is generally not present in the copolymer backbone.
[007Oi The indices m, n, o, and p are integers that take into account the use of different monomers and/or oligomers in the same copolymer or among a mixture of copolymers, where m is preferably 1, 2 or 3, n is preferably 1 or 2, o is preferably 1 or 2 and p is preferably 1, 2, 3 or 4.
[0071] In some embodiments at least two of Ar2, Ar3 and Ar4 are different from, each other. In another embodiment Ax2, Ar3 and Ar4 are each different from the other.
[0072] In some embodiments, when there is no hydrophobic oligomer , i.e. when c is zero in Formulas I, II, or III: (1) the precursor ion conductive monomer used to make the ion-conducting polymer is not 2,2' disulfonated 4,4' dihydroxy biphenyl; (2) the ion conductive polymer does not contain the ion-conducting monomer that is formed using this precursor ion conductive monomer; and/or (3) the ion-conducting polymer is not the polymer made according to Example 3 herein.
[0073] In some embodiments, a and c are zero and b and d are greater than zero in Formulas I, II and III. In this situation, random copolymers are generally made by use of at least three different precursor monomers where at least one is an ion conducting monomer and at least one of the precursor monomers contains a monomer with two leaving groups and at least one of the other two is a monomer with two displacement groups.
[0074] Formula IV is an example of a preferred end capped random coplolymer where n and m are mole fractions where n is between 0.5 and 0.9 and m is between 0.1 and 0.5. A preferred ratio is where n is 0.7 and m is 0.3.
Figure imgf000013_0001
[0075] Formula IV
[00761 Specific examples of this end capped random copolymer is set forth for the compounds used to make Membranes 1, 4 and 5. The polymers were end-capped by mono-fluorinated monomers (4-fluorobenzophenone F-K, 4-fluorobiphenyl F-B, and 4-fluorobenzonitrile F-CN) where a pre-determined amount of F-monomer was added at the beginning of each polymerization. In these examples the amounts of the precursors were chosen to result in the end capping of primarily one end of the polymer. In these membranes, n and m are as above for Formula IV.
Figure imgf000014_0001
Membrane 1
Figure imgf000014_0002
Membrane 4
Figure imgf000014_0003
Membrane 5
[00771 Table 2 discloses some of the monomers used to make ion-conductive copolymers.
1) Table 2. Precursor Difluoro-end monomers
Figure imgf000015_0001
2) Precursor Dihydroxy-end monomers
Figure imgf000015_0002
3) Precursor Dithiol-end monomers
Figure imgf000015_0003
[0078) The bifunctional precursor monomers and/or oligomers used to make the ion- conducting copolymer can be used as an end-capping monomer or oligomer by removal of one of the leaving or displacement groups. For example, the precursors of Rl and R2 can be: (1) a monovalent ion-conducting oligomer represented by the formulas (Y)-[-(ArI-T-)i-ArI]and [(ArrT-)i-Ari-]-(Y); ; (2) an ion-conducting monomer represented by the formulas (Y)-C-Ar2-U-Ar2) and (Ar2-U- Ar2-)-(Y); (3) a non-ionic oligomer represented by the formula (Y)-[(-Ar3-V-)j-Ar3]and [(Ar3- V-)j- Ar3-] -(Y) and (4) a non-ionic oligomer represented by the formula (Y)-C-Ar4-W-Ar4) and (Ar4-W- Ar4-)-(Y) where Y is a displacement of leaving group and th otrher terms are as set forth for Formulas I, II and III.
[0079] For example, the following non-ionic monovalent precursor monomers can be used:
Figure imgf000016_0001
[oo80] In some embodiments, the monovalent monomer or oligomer can further comprise an ion-conducting group such as sulfonic, phosphonic or carboxylic acids.
|oo8i] The ion conductive copolymers that can be end-capped include the random copolymers disclosed in US Patent Application No. 10/438,186, filed May 13, 2003, entitled "Sulfonated Copolymer," Publication No. US 2004-0039148 Al, published February 26, 2004, and US Patent Application No. 10/987,178, filed November 12, 2004, entitled "Ion Conductive Random Copolymer" and the block copolymers disclosed in US Patent Application No. 10/438,299, filed May 13, 2003, entitled "Ion Conductive Block Copolymers," published July 1, 2004, Publication No. 2004- 0126666. Other ion conductive copolymers include the oligomeric ion conducting polymers disclosed in US Patent Application No. 10/987,951, filed November 12, 2004, Publication No. 2005-0234146, published October 20, 2005,entitled "Ion Conductive Copolymers Containing One or More Hydrophobic Monomers or Oligomers," US Patent Application No. 10/988,187, filed November 11, 2004, Publication No. 2005-0282919, published December 22, 2005, entitled "Ion Conductive Copolymers Containing One or More Hydrophobic Oligomers" and US Patent Application No. 11/077,994, filed March 11, 2005, Publication No. 2006- 0041100, entitled "Ion Conductive Copolymers Containing One or More Ion conducting Oligomers." Each of the foregoing are incorporated herein by reference. As with Formulas I, II and III, the non-conductive polymer may be a copolymer having the same backbone as these copolymers without the ion conductive groups.
10082] Other ion-conducting copolymers and the monomers that can be used to make them include those disclosed in U.S. Patent Application No. 09/872,770, filed June 1, 2001, Publication No. US 2002-0127454 Al, published September 12, 2002, U.S. Patent Application No. 10/351,257, filed January 23, 2003, Publication No. US 2003- 0219640 Al, published November 27, 2003, U.S. Application No. 10/449,299, filed February 20, 2003, Publication No. US 2003-0208038 Al, published November 6, 2003, each of which are expressly incorporated herein by reference. Other ion- conducting copolymers that can be end-capped are made for comonomers such as those used to make sulfonated trifluorostyrenes (U.S. Patent No. 5,773,480), acid-base polymers, (U.S. Patent No. 6,300,381), poly arylene ether sulfones (U.S. Patent Publication No. US2002/0091225A1); graft polystyrene (Macromolecules 35:1348 (2002)); polyimides (U.S. Patent No. 6,586,561 and J. Membr. Sd. 160:127 (1999)) and Japanese Patent Applications Nos. JP2003147076 and JP2003055457, each of which are expressly identified herein by reference.
[00831 Although the end-capped copolymers of the invention have been described in connection with the use of arylene polymers, the ionic and non-ionic monomers or oligomers need not be arylene but rather may be aliphatic or perfluorinated aliphatic backbones containing ion-conducting groups. Ion-conducting groups may be attached to the backbone or maybe pendant to the backbone, e.g., attached to the polymer backbone via a linker. Alternatively, ion- conducting groups can be formed as part of the standard backbone of the polymer. See, e.g., U.S. 2002/018737781, published December 12, 2002 incorporated herein by reference. Any of these ion-conducting oligomers can be used to practice the present invention.
[0084] The mole percent of ion-conducting groups when only one ion-conducting group is present is preferably between 30 and 70%, or more preferably between 40 and 60%, and most preferably between 45 and 55%. When more than one conducting group is contained within the ion-conducting monomer, such percentages are multiplied by the total number of ion-conducting groups per monomer. Thus, in the case of a monomer comprising two sulfonic acid groups, the preferred sulfonation is 60 to 140%, more preferably 80 to 120% , and most preferably 90 to 110%. Alternatively, the amount of ion-conducting group can be measured by the ion exchange capacity (IEC). By way of comparison, Nation® typically has a ion exchange capacity of 0.9 meq per gram. In the present invention, it is preferred that the IEC be between 0.9 and 3.0 meq per gram, more preferably between 1.0 and 2.5 meq per gram, and most preferably between 1.6 and 2.2 meq per gram.
[00851 Although the end capped ion conducting copolymers have been described in connection with the use of arylene polymers, end capping can be applied to many other systems. For example, the ionic oligomers, non-ionic oligomers as well as the ionic and non-ionic monomers need not be arylene but rather may be aliphatic or perfluorinated aliphatic backbones containing ion-conducting groups. Ion-conducting groups may be attached to the backbone or may be pendant to the backbone, e.g., attached to the polymer backbone via a linker. Alternatively, ion-conducting groups can be formed as part of the standard backbone of the polymer. See, e.g., U.S. 2002/018737781, published December 12, 2002 incoiporated herein by reference. Any of these ion-conducting oligomers can be used to practice the present invention. [0086] Polymer membranes may be fabricated by solution casting of the ion- conductive copolymer. When cast into a membrane for use in a fuel cell, it is preferred that the membrane thickness be between 0.1 to 10 mils, more preferably between 1 and 6 mils, most preferably between 1.5 and 2.5 mils.
[0087] As used herein, a membrane is permeable to protons if the proton flux is greater than approximately 0.005 S/cm, more preferably greater than 0.01 S/cm, most preferably greater than 0.02 S/cm.
[0088] As used herein, a membrane is substantially impermeable to methanol if the methanol transport across a membrane having a given thickness is less than the transfer of methanol across a Nafion membrane of the same thickness. In preferred embodiments the permeability of methanol is preferably 50% less than that of a Nafion membrane, more preferably 75% less and most preferably greater than 80% less as compared to the Nafion membrane.
[0089] After the ion-conducting copolymer has been formed into a membrane, it may be used to produce a catalyst coated membrane (CCM). As used herein, a CCM comprises a PEM when at least one side and preferably both of the opposing sides of the PEM are partially or completely coated with catalyst. The catalyst is preferable a layer made of catalyst and ionomer. Preferred catalysts are Pt and Pt-Ru. Preferred ionomers include Nafion and other ion-conductive polymers. In general, anode and cathode catalysts are applied onto the membrane using well established standard techniques. For direct methanol fuel cells, platinum/ruthenium catalyst is typically used on the anode side while platinum catalyst is applied on the cathode side. For hydrogen/air or hydrogen/oxygen fuel cells platinum or platinum/ruthenium is generally applied on the anode side, and platinum is applied on the cathode side. Catalysts may be optionally supported on carbon. The catalyst is initially dispersed in a small amount of water (about lOOmg of catalyst in 1 g of water). To this dispersion a 5% ionomer solution in water/alcohol is added (0.25-0.75 g). The resulting dispersion may be directly painted onto the polymer membrane. Alternatively, isopropanol (1-3 g) is added and the dispersion is directly sprayed onto the membrane. The catalyst may also be applied onto the membrane by decal transfer, as described in the open literature {Electrochimica Acta, 40: 297 (1995)).
[0090] The CCM is used to make MEA's. As used herein, an MEA refers to an ion- conducting polymer membrane made from a CCM according to the invention in combination with anode and cathode electrodes positioned to be in electrical contact with the catalyst layer of the CCM.
[009i] The electrodes are in electrical contact with the catalyst layer, either directly or indirectly via a gas diffusion or other conductive layer, so that they are capable of completing an electrical circuit which includes the CCM and a load to which the fuel cell current is supplied. More particularly, a first catalyst is electrocatalytically associated with the anode side of the PEM so as to facilitate the oxidation of hydrogen or organic fuel. Such oxidation generally results in the formation of protons, electrons and, in the case of organic fuels, carbon dioxide and water. Since the membrane is substantially impermeable to molecular hydrogen and organic fuels such as methanol, as well as carbon dioxide, such components remain on the anodic side of the membrane. Electrons formed from the electrocatalytic reaction are transmitted from the anode to the load and then to the cathode. Balancing this direct electron current is the transfer of an equivalent number of protons across the membrane to the cathodic compartment. There an electrocatalytic reduction of oxygen in the presence of the transmitted protons occurs to form water. In one embodiment, air is the source of oxygen. In another embodiment, oxygen-enriched air or oxygen is used.
[0092] The membrane electrode assembly is generally used to divide a fuel cell into anodic and cathodic compartments. In such fuel cell systems, a fuel such as hydrogen gas or an organic fuel such as methanol is added to the anodic compartment while an oxidant such as oxygen or ambient air is allowed to enter the cathodic compartment. Depending upon the particular use of a fuel cell, a number of cells can be combined to achieve appropriate voltage and power output. Such applications include electrical power sources for residential, industrial, commercial power systems and for use in locomotive power such as in automobiles. Other uses to which the invention finds particular use includes the use of fuel cells in portable electronic devices such as cell phones and other telecommunication devices, video and audio consumer electronics equipment, computer laptops, computer notebooks, personal digital assistants and other computing devices, GPS devices and the like. In addition, the fuel cells may be stacked to increase voltage and current capacity for use in high power applications such as industrial and residential sewer services or used to provide locomotion to vehicles. Such fuel cell structures include those disclosed in U.S. Patent Nos. 6,416,895, 6,413,664, 6,106,964, 5,840,438, 5,773,160, 5,750,281, 5,547,776, 5,527,363, 5,521,018, 5,514,487, 5,482,680, 5,432,021, 5,382,478, 5,300,370, 5,252,410 and 5,230,966.
[0093] Such CCM and MEM's are generally useful in fuel cells such as those disclosed in U.S. Patent Nos. 5,945,231, 5,773,162, 5,992,008, 5,723,229, 6,057,051, 5,976,725, 5,789,093, 4,612,261, 4,407,905, 4,629,664, 4,562,123, 4,789,917, 4,446,210, 4,390,603, 6,110,613, 6,020,083, 5,480,735, 4,851,377, 4,420,544, 5,759,712, 5,807,412, 5,670,266, 5,916,699, 5,693,434, 5,688,613, 5,688,614, each of which is expressly incorporated herein by reference.
[0094] The CCM's and MEA's of the invention may also be used in hydrogen fuel cells that are known in the art. Examples include 6,630,259; 6,617,066; 6,602,920; 6,602,627; 6,568,633; 6,544,679; 6,536,551; 6,506,510; 6,497,974, 6,321,145; 6,195,999; 5,984,235; 5,759,712; 5,509,942; and 5,458,989 each of which are expressly incorporated herein by reference.
[00951 The ion-conducting polymer membranes of the invention also find use as separators in batteries. Particularly preferred batteries are lithium ion batteries.
EXAMPLES
I. Random Copolymerizations
[0096] In the current study, the molar % of the mono-fluorinated monomer used to end-cap the random copolymer BisZ (i.e., mole % of the non-flourinated monomers) was adjusted to 1 mol%, 2 mol%, and 5 mol% for F-K, and 1 mol% both for F-B and F-CN, to ensure that OH end groups can be fully end-capped.
Comparative 1 :
[0097] In a 500 niL three necked round flask, equipped with a mechanical stirrer, a thermometer probe connected with a nitrogen inlet, and a Dean-Stark trap/condenser, 4,4'-difluorobenzoρhenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'- difiuorobenzophenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4- hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), , and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene. The reaction mixture was slowly stirred under a slow nitrogen stream. After heating at ~85 0C for 1 h and at ~120°C for 1.5 h, the reaction temperature was raised to 140 0C for 1.5 h, and at 155 0C for 1 h, finally to 170 0C for 2 h. After cooling to 70 0C with continuing stirring, the solution was dropped into 2 L of cooled methanol with a vigorous stirring. The precipitates were filtrated and washed with Di-water four times and dried at 80 0C for one day. The sodium form polymer was exchanged to acid form by washing the polymer in hot sulfuric acid solution (1.5 M) twice (1 h each) and in cold di-water twice. The polymer was then dried at 80 0C overnight and at 80 0C under vacuum for additional day. This polymer has an inherent viscosity of 1.20 dl/g in DMAc (0.25 g/dl).
Example 1 with 1 mol% endcapper 4-fluorobenzophenone:
[0098] This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobenzophenone (F-K, 0.25g, 0.00125 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 1 12 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 0.98 dl/g in DMAc (0.25 g/dl). Example 2 with 2 mol% endcapper 4-fluorobenzophenone:
[0099] This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g5 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzoρhone (SBisK, 15.84 g, 0.0375 mol), 1,1- bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobenzophenone (F-K, 0.50 g, 0.0025 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 niL of DMSO and 112 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 0.90 dl/g in DMAc (0.25 g/dl).
Example 3 with 5 mol% endcapper 4-fluorobenzophenone:
[ooioo] This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 rnol), 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobenzophenone (F-K, 1.25 g, 0.00625 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 0.42 dl/g in DMAc (0.25 g/dl).
Example 4 with 1 mol% endcapper 4-biphenyI:
tooioi] This polymer was synthesized in a similar way as described in comparative 1 , using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzoρhenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobiphenyl (0.215 g, 0.00125 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 1.18 dl/g in DMAc (0.25 g/dl).
Example 5 with 1 mol% endcapper 4-fluorobenzonitrile:
[ooio2] This polymer was synthesized in a similar way as described in comparative I5 using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzoρhenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (33.54 g, 0.125 mol), 4-fluorobenzonitrile (0.154 g, 0.00125 mol), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 1.18 dl/g in DMAc (0.25 g/dl).
[00103] Results
[ooio4] Table 3 summarizes data on polymer 1-5 made according to Examples 1-5. With introduction of 1 mol% end-capping monomers, the polymers synthesized have good molecular weights. As expected, the polymer end-capped with 5 mol% F-K has a very low molecular weight due to the unbalanced stoichiometry. A close look on the Z-K series reveals that these polymers have good polydispersities (<2.3), whereas the non-encapped comparative example 1 has a PDI of 2.8.
[00105] Table 3. Characterization of End-capping random polymers
Polymer IV. IEC Mπ/Mw/Mz/PDI Mn/Mw/Mz/PDI Na form/acid form Polymer Polymer Na form Polymer acid form 104/104/104/-- loVioVio4/-
Polymer 1 1.16/1.05 1.15 4.86/11.08/23.27/2.28 4.52/9.53/18.82/2.11
Polymer 2 1.05./1.02 1.14 4.31/9.36/19.21/2.17 4.30/8.76/17.69/2.04
Polymer 3 0.42/NA NA 1.76/2.72/4.61/1.55 NA
Polymer 4 1.30/1.15 1.15 N/A N/A
Polymer 5 1.42/1.20 1.15 N/A N/A
[ooiθ6] The end-capped polymers except polymer 3 (due to its low molecular weight) were cast into membranes from DMAc solutions. Table 4 summarizes ex-situ data from these membranes. Reduced LV. s and IECs from polymers to membranes were observed in almost all cases, indicating there was some degradation during coating process. However, the degree of these losses is less than that of the non-end-capped membrane. MEAs were also fabricated from some of these membranes for DMFC testing. With 1 M methanol concentration and operation temperature at 60 C, MEA 1 from membrane 1 has a power density at 138 mW/cm2 at 0.4 V, and methanol crossover of 46 mA/cm2, whereas comparative membrane 1 has a power at 124 mW/cm2 and a crossover of 53 mA/cm2.
[001071 Table 4. Membrane Ex-Situ Data Summary
Membrane LV. IEC Water Swelling Conductivity Polymer/ Polymer/ Uptake (%) 60C/Boiled Membrane Membrane (%) (S/cm)
Membrane 1 0.98/0.98 1.16/0.99 23.9 28.5 0.018/0.031
Membrane 2 0.90/0.88 1.16/NA 23,9 29.0 0.017/0.030
Membrane 4 1.18/1.14 1.15/1.05 24.3 29.5 0.022/0.032
Membrane 5 1.18/1.15 1.15/1.05 23.5 28.5 0.021/0.032
Comparative 1 1.20/1.10 1.13/0.98 22.4 30.0 0.017/0.034
I00108] Ex-situ data for end-capped membranes 6-9 and comparative 2 are summarized in Table 5. Both membranes 7 and 8 have higher swelling, due to lower molecular weights. Membranes 6 and 9 have comparable performance to comparative 2. These membranes are fabricated into MEAs and they show good performance in H2/Air fuel cell operation.
[00109] Table 5. Membrane Ex-Situ Data Summary
Membrane LV. IEC Water Swelling Conductivity Polymer Polymer Uptake (%) 60C/Boiled (%) (S/cm) Membrane 6 1.64 2.15 58 53 0.118/0.122
Membrane 7 1.00 1.93 166 130 0.098/0.075
Membrane 8 1.57 1.88 166 125 0.099/0.072
Membrane 9 2.06 2.08 72 53 0.087/0.100
Comparative 2 1.79 2.15 71 51 0.110/0.120
[ooi 10] The polarization curves for Membranes 6 and 9 are set forth in FIG. 1 and FIG. 2. II. Block Copolymerizations
Oligomer 1 with fluoride ending groups:
[ooiii] In a 500 mL three necked round flask, equipped with a mechanical stirrer, a thermometer probe connected with a nitrogen inlet, and a Dean-Stark trap/condenser, 4,4'-difluorobenzophone (BisK, 28.36 g, 0.13 mol), 4,4'- dihydroxytetraphenylmethane (34.36 g, 0.0975 mol), and anhydrous potassium carbonate (17.51 g, 0.169 mol), 234 mL of DMSO and 117 mL of Toluene. The reaction mixture was slowly stirred under a slow nitrogen stream. After heating at ~85 0C for Ih and at -1200C for 1 h, the reaction temperature was raised to -135 0C for 3 h, and finally to -1700C for 2 h. After cooling to -70 0C with continuing stirring, the solution was dropped into 2 L of cooled methanol with a vigorous stirring. The precipitates were filtrated and washed with Di-water four times and dried at 80 0C for one day and at 80 0C under a vacuum oven for 2 days.
Oligomer 2 with fluoride ending groups:
[00U2] This oligomer was synthesized in a similar way as described in oligomer 1, using following compositions: bis(4-fluorophenyl) sulfone (63.56 g, 0.25 mol), 4,4'- dihydroxytetraphenylmethane (66.08 g, 0.1875 mol), and anhydrous potassium carbonate (33.67 g, 0.325 mol), 450 mL of DMSO and 225 mL of Toluene.
Comparative 2:
loons] In a 500 mL three necked round flask, equipped with a mechanical stirrer, a thermometer probe connected with a nitrogen inlet, and a Dean-Stark trap/condenser, 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 25.42 g), Oligomer 1 (22.93 g), 4,4'-biphenol (13.03 g), and anhydrous potassium carbonate (12.58 g), were added together with a mixture of anhydrous DMSO (234 mL) and freshly distilled toluene (117 mL). The reaction mixture was slowly stirred under a slow nitrogen stream. After heating at 850C for 1 h and at 1200C for 1 h, the reaction temperature was raised to 140 0C for 2 h, and finally to 163 0C for 2 h. After cooling to -70 0C with continuing stirring, the viscous solution was dropped into IL of cooled methanol with a vigorous stirring. The noodle-like precipitates were cut and washed with di-water four times and dried at 80 0C overnight. The sodium form polymer was exchanged to acid form by washing the polymer in hot sulfuric acid solution (1.5 M) twice (1 h each) and in cold di-water twice. The polymer was then dried at 80 0C overnight and at 80 0C under vacuum for 2 days. This polymer has an inherent viscosity of 1.79 dl/g in DMAc (0.25 g/dl).
Example 6 end-capped with 2.2 mol% 4-fluorobiphenyI:
[ooii4] This polymer was synthesized in a similar way as described in comparative 2, using following compositions: 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 25.42 g), Oligomer 1 (22.93 g), 4,4'-biphenol (13.03 g), 4-fluorobiphenyl (0.265 g), and anhydrous potassium carbonate (12.58 g), were added together with a mixture of anhydrous DMSO (234 mL) and freshly distilled toluene (117 mL). This polymer after acid treatment has an inherent viscosity of 1.64 dl/g in DMAc (0.25 g/dl).
Example 7 end-capped with 2.2 mol% 4-fluorobiphenyl:
loons] This polymer was synthesized in a similar way as described in comparative 2, using following compositions: 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 22.30 g), Oligomer 1 (16.85 g), 4,4'-(hexafluoroisoproρylidene)diphenol (20.37 g), 4-fluorobiphenyl (0.227 g), and anhydrous potassium carbonate (10.83 g), were added together with a mixture of anhydrous DMSO (228 mL) and freshly distilled toluene (114 mL). This polymer after acid treatment has an inherent viscosity of 1.00 dl/g in DMAc (0.25 g/dl).
Example 8 end-capped with 2.2 mol% 4-fluorobiphenyl:
[O0H6] This polymer was synthesized in a similar way as described in comparative 2, using following compositions: 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 22.30 g), Oligomer 2 (18.15 g), 4,4'-(hexafluoroisopropylidene)diphenol (20.37 g), 4-fluorobiphenyl (0.227 g), and anhydrous potassium carbonate (10.83 g), were added together with a mixture of anhydrous DMSO (234 mL) and freshly distilled toluene (117 mL). This polymer after acid treatment has an inherent viscosity of 1.57 dl/g in DMAc (0.25 g/dl).
Example 9 end-capped with 2.2 mol% 4-fluorobiphenyI:
[ooii7] This polymer was synthesized in a similar way as described in comparative 2, using following compositions: 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 21.79 g), Oligomer 2 (21.17 g), 4,4'-biphenol (11.28 g), 4-fluorobiphenyl (0.227 g), and anhydrous potassium carbonate (10.83 g), were added together with a mixture of anhydrous DMSO (228 mL) and freshly distilled toluene (114 mL). This polymer after acid treatment has an inherent viscosity of 2.06 dl/g in DMAc (0.25 g/dl).
Example 10 with 0.25 mol% end capper 4-t-butyIphenol:
toons] This polymer was synthesized in a similar way as described in comparative 1, using following compositions: 4,4'-difluorobenzophenone (BisK, 19.09 g, 0.0875 mol), 3,3'-disulfonated-4,4'-difluorobenzophenone (SBisK, 15.84 g, 0.0375 mol), l,l-bis(4-hydroxyphenyl)cyclohexane (32.70 g), 4-t-butylphenol (0.469 g), and anhydrous potassium carbonate (22.46 g, 0.165 mol), 225 mL of DMSO and 112 mL of Toluene. This polymer after acid treatment has an inherent viscosity of 1.26 dl/g in DMAc (0.25 g/dl). Its membrane swelling is 19.5%, water uptake is 21%, conductivity is 0.018 S/cm at 60 C and 0.031 S/cm after boiled, respectively.

Claims

WHAT IS CLAIMED IS:
1. An end capped ion conductive copolymer having the formula Rr[[(-ArrT-)rAr,-X-] * / (-Ar2-U-Ar2-X-);1 / [(-Ar3-V-VAr3-X-] ' / (-Ar4-W-Ar4-X-) J /]-R2 wherein Ar1, Ar2, Ar3 and Ar4 are aromatic moieties; at least one of ArI comprises an ion-conducting group; at least one of Ar2 comprises an ion-conducting group;
T, U, V and W are linking moieties;
X are independently -O- or -S-; i and j are independently integers greater than 1; a, b, c, and d are mole fractions wherein the sum of a, b ,c and d is 1, a is zero or greater than 0 and at least two of b, c and d is greater than 0; m, n, o, and p are integers indicating the number of different oligomers or monomers in the copolymer; and
R1 and R2 are end-capping monomers and/or oligomers where at least one of Ri and R2 is present in said copolymer.
2. The end capped ion-conductive copolymer of Claim 1 wherein: Ar1, Ar2, Ar3 and Ar4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile; and
T3U5V and W are independently a bond O, S, C(O), S(O2), alkyl, branched alkyl, fluoroalkyl, branched fluoroalkyl, cycloalkyl, aryl, substituted aryl or heterocycle.
3. The end capped ion-conductive copolymer of Claim 1 wherein: Ari, Ar2, Ar3 and Ar4 are independently phenyl, substituted phenyl, napthyl, terphenyl, aryl nitrile and substituted aryl nitrile; and
T, U, V and W are independently a bond, -C(O)-,
Figure imgf000030_0001
4. An end capped ion conducting polymer having the formula
Figure imgf000030_0002
wherein m and n are mole fractions; Rj and R2 are end-capping monomers and/or oligomers and at least one of Ri and R2 is present in said copolymer.
5. A polymer electrolyte membrane (PEM) comprising the ion- conducting copolymer of claim 1 or 4.
6. A catalyst coated membrane (CCM) comprising the PEM of claim 5 wherein all or part of at least one opposing surface of said PEM comprises a catalyst layer.
7. A membrane electrode assembly (MEA) comprising the CCM of claim
6.
8. A fuel cell comprising the MEA of claim 7.
9. The fuel cell of claim 8 comprising a hydrogen fuel cell.
10. An electronic device comprising the fuel cell of claim 8.
11. A power supply comprising the fuel cell of claim 8.
12. An electric motor comprising the fuel cell of claim 8.
13. A vehicle comprising the electric motor of claim 12.
PCT/US2006/020736 2005-05-27 2006-05-30 End-capped ion-conductive polymers WO2006128106A2 (en)

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