Method for Laminating a Polymer Electrolyte Film onto a Porous Support Layer for Energy Storage Devices

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This invention presents a method for producing a composite electrolyte membrane by laminating a thin polymer electrolyte film onto a porous support layer. The process creates a strong mechanical bond via a controlled partial solubilization of the polymer, enabling the polymer to flow into the pores of the support layer and form an interlocking interface. The resulting composite membrane is especially designed for use in electrochemical energy storage or conversion devices such as redox flow batteries, fuel cells, and electrolyzers, offering excellent mechanical stability with low electrical resistance.

Use CasesContent extracted from patent full text and abstract with AI.

• Polymer electrolyte membranes in redox flow batteries for grid-scale energy storage.
• Electrolyte membranes in fuel cells for clean power generation in vehicles or stationary applications.
• Membranes in electrolyzers for hydrogen production from water splitting.
• Advanced separators in lithium-ion or other rechargeable batteries.
• Electrochemical cells for industrial processes where selective ion transport and mechanical robustness are required.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly improved adhesion between polymer film and porous support, reducing risk of delamination during device operation.
• Allows the use of thinner electrolyte films, minimizing ohmic (electrical) resistance and improving efficiency.
• Enhanced mechanical strength and robustness of the membrane, preventing ruptures and pinholes during manufacturing and use.
• Broad compatibility with various polymer materials for both the electrolyte film and the porous support layer, increasing flexibility for different device needs.
• Tunability of membrane properties through control of polymer/solvent mixtures and process parameters.
• Maintains high coulombic, voltaic, and energy efficiencies in energy storage devices, with stable performance across many charge-discharge cycles.
• Facilitates more compact and durable electrochemical cell designs for energy and industrial applications.

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Patent Abstract

The present invention discloses a composite electrolyte membrane and a method to fabricate it. The composite electrolyte membrane is meant to be used in an electrochemical energy storage or conversion device, including but not limiting to redox flow batteries, fuel cells and electrolyzers.The composite electrolyte membrane is produced according to a method for laminating a polymer electrolyte film onto a porous support layer for generating a composite membrane for energy storage devices; comprising the following steps:a) placing the polymer electrolyte film on a first flat support plate;b) placing the porous support layer on the polymer electrolyte film;c) wetting the porous support layer with a first solution comprising a first solvent, which is a high boiling point solvent, used to partially solubilize the polymer electrolyte film allowing its solubilized fraction to flow into the pores of the porous support and a second solvent, which is a low boiling point solvent, to prevent excessive solubilization of the polymer electrolyte film, wherein the solubilized fraction of the polymer electrolyte film formsan interlocking interface with a superficial part of the porous support layer;d) placing a second flat support plate, preferably with two tissues to absorb solvent excess, on the wetted porous support layer to form a stack having sandwiched the polymer electrolyte film, the interlocking interface and the porous support layer between the first and the second flat support plates;e) hot-pressing the stack at an elevated temperature and an elevated pressure for a pre-defined amount of time; andf) cooling down the hot-pressed stack and removing the first and the second flat support plate to isolate the composite membrane comprising i) the polymer electrolyte film, ii) the now solidified and formerly solubilized fraction of the polymer electrolyte film penetrated into the pores of the porous support layer forming a solidified interlocking interface and iii) the porous support layer.