US2009324929A1PendingUtilityA1

Composite Membrane and Moisture Adjustment Module Using Same

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Assignee: YAMAKAWA KEIICHIPriority: Jun 25, 2008Filed: Sep 26, 2008Published: Dec 31, 2009
Est. expiryJun 25, 2028(~1.9 yrs left)· nominal 20-yr term from priority
Inventors:Keiichi YamakawaWiliam B. JohnsonMahesh MurthyThomas Berta
H01M 2008/1095B01D 2319/06B01D 2313/14B01D 2323/30H01M 8/1053Y10T428/249991Y10T428/24998H01M 8/1081H01M 8/1018B01D 2325/42B01D 2325/20B01D 2325/38H01M 8/1062H01M 8/1067Y10T156/10H01M 8/04149H01M 8/106H01M 8/1039B01D 2325/04H01M 8/1023B01D 71/32H01M 2300/0082B01D 2325/36B01D 63/082B01D 69/1213B01D 2323/081B01D 71/381B01D 2325/02833B01D 67/0013C08J 5/18H01M 8/0239H01M 8/10Y02E60/50Y02P70/50
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Claims

Abstract

A composite membrane and moisture adjustment module using the same is disclosed. The composite membrane includes a moisture-permeable resin layer interposed between porous membranes that constitute a pair; and the mean thickness of the moisture-permeable resin layer is 5 μm or less.

Claims

exact text as granted — not AI-modified
1 . A composite membrane wherein:
 a moisture-permeable resin layer is interposed between porous membranes that constitute a pair; and   the mean thickness of the moisture-permeable resin layer is 5 μm or less.   
   
   
       2 . The composite membrane according to  claim 1 , wherein said moisture-permeable resin comprises a water-resistant, moisture-permeable resin. 
   
   
       3 . The composite membrane according to  claim 2 , wherein the degree of swelling of said water-resistant, moisture-permeable resin, is 20 times or less. 
   
   
       4 . The composite membrane according to  claim 2  wherein said water-resistant, moisture-permeable resin comprises a crosslinked polyvinyl alcohol. 
   
   
       5 . The composite membrane according to  claim 2 , wherein said water-resistant, moisture-permeable resin comprises an ion-exchange fluororesin. 
   
   
       6 . The composite membrane according to  claim 5 , wherein said water-resistant, moisture-permeable resin comprises a perfluorosulfonic acid polymer. 
   
   
       7 . The composite membrane according to  claim 3  wherein said water-resistant, moisture-permeable resin comprises a crosslinked polyvinyl alcohol. 
   
   
       8 . The composite membrane according to  claim 1  wherein at least part of said moisture-permeable resin is embedded in the porous membrane. 
   
   
       9 . The composite membrane according  claim 4  wherein at least part of said moisture-permeable resin is embedded in the porous membrane. 
   
   
       10 . The composite membrane according  claim 6  wherein at least part of said moisture-permeable resin is embedded in the porous membrane. 
   
   
       11 . The composite membrane according  claims 1  wherein:
 the mean pore diameter of the said porous membranes is 0.05 μm or greater; and   the maximum pore diameter is 15 μm or less.   
   
   
       12 . The composite membrane according  claims 4  wherein:
 the mean pore diameter of said porous membranes is 0.05 μm or greater; and the maximum pore diameter is 15 μm or less.   
   
   
       13 . The composite membrane according  claims 6  wherein:
 the mean pore diameter of said porous membranes is 0.05 μm or greater; and the maximum pore diameter is 15 μm or less.   
   
   
       14 . The composite membrane according to  claim 1  wherein the void content of the said porous membranes is 40% or greater. 
   
   
       15 . The composite membrane according to  claim 4  wherein the void content of the said porous membranes is 40% or greater. 
   
   
       16 . The composite membrane according to  claim 6  wherein the void content of the said porous membranes is 40% or greater. 
   
   
       17 . The composite membrane according to  claim 1  wherein the mean thickness of said porous membranes is 1 to 200 μm. 
   
   
       18 . The composite membrane according to  claim 4  wherein the mean thickness of said porous membranes is 1 to 200 μm. 
   
   
       19 . The composite membrane according to  claim 6  wherein the mean thickness of said porous membranes is 1 to 200 μm. 
   
   
       20 . The composite membrane according to any of  claims 1  wherein at least one of said porous membranes comprises a expanded polytetrafluoroethylene membrane. 
   
   
       21 . The composite membrane according to any of  claims 4  wherein at least one of said porous membranes comprises a expanded polytetrafluoroethylene membrane. 
   
   
       22 . The composite membrane according to any of  claims 6  wherein at least one of said porous membranes comprises a expanded polytetrafluoroethylene membrane. 
   
   
       23 . The composite membrane according to  claims 1  wherein a gas-permeable reinforcing element is layered on at least one of the porous membranes. 
   
   
       24 . The composite membrane according to  claims 4  wherein a gas-permeable reinforcing element is layered on at least one of the porous membranes. 
   
   
       25 . The composite membrane according to  claims 6  wherein a gas-permeable reinforcing element is layered on at least one of the porous membranes. 
   
   
       26 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 1  while open spaces are left therebetween. 
   
   
       27 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 4  while open spaces are left therebetween. 
   
   
       28 . A moisture adjustment module, obtained by superposing the composite membrane of  claim 6  while open spaces are left therebetween. 
   
   
       29 . A composite membrane wherein an air-impermeable layer comprising a perfluorosulfonic acid polymer is interposed between a first and second micro-porous membrane. 
   
   
       30 . A composite membrane of  claim 29  wherein at least one of said first and second micro-porous membranes is hydrophobic. 
   
   
       31 . A composite membrane of  claim 29  wherein at least one of said first and second micro-porous membranes is hydrophilic. 
   
   
       32 . A composite membrane of  claim 29  wherein said perfluorosulfonic acid polymer further comprises a reinforcement. 
   
   
       33 . A composite membrane of  claim 29  wherein said air impermeable layer has a mean thickness less than 20 um. 
   
   
       34 . The composite membrane according to  claim 29  wherein at least part of said impermeable layer is embedded in the micro-porous membrane. 
   
   
       35 . The composite membrane according to  claim 29  wherein at least one of said first and second micro-porous layers comprises expanded polytetrafluoroethylene. 
   
   
       36 . A composite membrane of  claim 32  wherein said reinforcement comprises particulates. 
   
   
       37 . A composite membrane of  claim 32  wherein said reinforcement comprises a third micro-porous membrane. 
   
   
       38 . A composite membrane of  claim 37  wherein said third micro-porous membrane comprises expanded polytetrafluoroethylene. 
   
   
       39 . A composite membrane of  claim 29  wherein at least one of said first and second micro-porous membranes has a reinforcing member attached to it. 
   
   
       40 . A moisture-permselective membrane of  claim 39  wherein said reinforcing member is a non-woven material. 
   
   
       41 . A moisture-permselective membrane of  claim 39  wherein said reinforcing member is a woven material. 
   
   
       42 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 29  while open spaces are left therebetween. 
   
   
       43 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 32  while open spaces are left therebetween. 
   
   
       44 . A method of preparing a composite membrane comprising the steps of
 a. Casting a solution comprising a moisture permselective resin on a first micro-porous membrane to form a film on the surface of said micro-porous membrane;   b. Stretching a second micro-porous membrane over said film before it is dry to form a composite structure;   c. Drying said composite structure to remove residual liquid from said solution.   
   
   
       45 . A method of  claim 44  wherein said film is between 0.5 and 10 um thick after step c. 
   
   
       46 . A method of  claim 44  wherein an additional step of heat-treating said composite membrane after step (c) is performed. 
   
   
       47 . The method of  claim 44  wherein a reinforcing member is laminated to at least one side of said composite membrane after step c. 
   
   
       48 . A method of  claim 46  wherein said heat treatment comprises holding said composite membrane at a temperature between 100 and 180 C for a period of time between 1 and 15 minutes. 
   
   
       49 . A method of preparing a composite membrane comprising the steps of:
 a. Preparing a membrane having two sides, said membrane comprising a moisture permselective resin;   b. Laminating one side of said membrane to a first micro-porous membrane;   c. Laminating a second micro-porous membrane to the second side of said membrane.   
   
   
       50 . The method of  claim 49  wherein at least one of the first micro-porous membrane and the second micro-porous membrane comprise expanded polytetrafluoroethylene. 
   
   
       51 . The method of  claim 49  wherein said membrane comprising moisture permselective resin further comprises expanded polytetrafluoroethylene. 
   
   
       52 . The method of  claim 49  wherein said membrane comprising moisture permselective resin comprises a perfluorosulfonic acid polymer. 
   
   
       53 . The method of  claim 49  wherein a reinforcing member is laminated to at least one side of said composite membrane after step c. 
   
   
       54 . The method of  claim 49  wherein said membrane comprising moisture permselective resin in step (a) has a mean thickness of less than 15 μm. 
   
   
       55 . The method of  claim 49  wherein said membrane comprising moisture permselective resin in step (a) has a mean thickness of less than 6 μm. 
   
   
       56 . A composite membrane wherein an air-impermeable layer comprising an ionomeric polymer is interposed between a first and second micro-porous membrane. 
   
   
       57 . A composite membrane of  claim 56  wherein at least one of said first and second micro-porous membranes is hydrophobic. 
   
   
       58 . A composite membrane of  claim 56  wherein at least one of said first and second micro-porous membranes is hydrophilic. 
   
   
       59 . A composite membrane of  claim 56  wherein said perfluorosulfonic acid polymer further comprises a reinforcement. 
   
   
       60 . A composite membrane of  claim 56  wherein said air impermeable layer has a mean thickness less than 20 um. 
   
   
       61 . The composite membrane according to  claim 56  wherein at least part of said impermeable layer is embedded in the micro-porous membrane. 
   
   
       62 . The composite membrane according to  claim 56  wherein at least one of said first and second micro-porous layers comprises expanded polytetrafluoroethylene. 
   
   
       63 . A composite membrane of  claim 59  wherein said reinforcement comprises particulates. 
   
   
       64 . A composite membrane of  claim 59  wherein said reinforcement comprises a third micro-porous membrane. 
   
   
       65 . A composite membrane of  claim 64  wherein said third micro-porous membrane comprises expanded polytetrafluoroethylene. 
   
   
       66 . A composite membrane of  claim 56  wherein at least one of said first and second micro-porous membranes has a reinforcing member attached to it. 
   
   
       67 . A moisture-permselective membrane of  claim 66  wherein said reinforcing member is a non-woven material. 
   
   
       68 . A moisture-permselective membrane of  claim 66  wherein said reinforcing member is a woven material. 
   
   
       69 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 56  while open spaces are left therebetween. 
   
   
       70 . A moisture adjustment module, obtained by superposing the composite membrane of  claims 59  while open spaces are left therebetween.

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