# US 10,865,282 B2 · Ion exchange membrane, method for producing ion exchange membrane, and electrolyzer

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- Number: US 10,865,282 B2
- Document ID: US10865282B2
- Status: Granted
- Kind: B2
- Application number: 16/219,100
- Filed: 2018-12-13
- Published: 2019-07-04
- Granted: 2020-12-15
- Earliest claimed: 2017-12-18
- Assignees: Asahi Kasei Kabushiki Kaisha
- Applicants: Asahi Kasei Kabushiki Kaisha
- Inventors: Koji Okamoto; Kazuya Takahashi
- Web page: https://patentgrep.com/patent/US10865282B2

## CPC

- C08J 5/225: {containing fluorine}
- B01D 69/1071: {Woven, non-woven or net mesh}
- B01D 69/1212: {Coextruded layers}
- B01D 69/1213: {Laminated layers}
- B01D 69/1216: {Three or more layers}
- B01D 69/148: {Organic/inorganic mixed matrix membranes}
- B01D 71/024: {Oxides}
- B01D 71/32: containing fluorine atoms
- C08J 5/2237: {containing fluorine}
- C08J 5/2293: {After-treatment of fluorine-containing membranes}
- C08J 7/0423: {with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder}
- C08J 7/0427: {with only one layer of a composition containing a polymer binder (with more layers C08J7/042)}
- C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50)
- C08J 7/056: Forming hydrophilic coatings
- C25B 1/16: Hydroxides (by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34)
- C25B 1/26: Chlorine; Compounds thereof (by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34)
- C25B 1/46: in diaphragm cells
- C25B 9/19: with diaphragms
- C25B 9/23: comprising ion-exchange membranes in or on which electrode material is embedded
- C25B 13/08: based on organic materials
- B01D 2323/26: Spraying processes
- B01D 2323/36: Introduction of specific chemical groups
- B01D 2323/60: Co-casting; Co-extrusion
- B01D 2325/22: Thermal or heat-resistance properties
- B01D 2325/30: Chemical resistance
- B01D 2325/42: Ion-exchange membranes
- C08J 2327/18: Homopolymers or copolymers of tetrafluoroethylene
- C08J 2427/18: Homopolymers or copolymers of tetrafluoroethylene
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- C25B: ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR (anodic or cathodic protection C23F13/00; single-crystal growth C30B)

## Abstract

An ion exchange membrane includes: a membrane main body including a fluorine-containing polymer having an ion exchange group; and a coating layer arranged on at least one face of the membrane main body; wherein the coating layer includes inorganic particles and a binder, a mass ratio of the binder to the total mass of the inorganic particles and the binder in the coating layer is more than 0.3 and 0.9 or less, and a surface roughness of the coating layer is 1.20 μm or more.

## Claims

### Claim 1

An ion exchange membrane comprising:
a membrane main body comprising a fluorine-containing polymer having an ion exchange group; and
a coating layer arranged on at least one face of the membrane main body;
wherein
the coating layer comprises inorganic particles and a binder, wherein
the average particle size of the inorganic particles is 0.90 μm or more and 2 μm or less, and
a mass ratio of the binder to a total mass of the inorganic particles and binder in the coating layer is more than 0.3 and 0.9 or less, and a surface roughness of the coating layer is 1.20 μm or more.

### Claim 2 (depends on 1)

The ion exchange membrane according to claim 1,
wherein the inorganic particles are particles comprising at least one mineral selected from the group consisting of oxides of Periodic Table Group IV elements, nitrides of Periodic Table Group IV elements, and carbides of Periodic Table Group IV elements.

### Claim 3 (depends on 1)

The ion exchange membrane according to claim 1,
wherein the inorganic particles are particles of zirconium oxide.

### Claim 4 (depends on 1)

The ion exchange membrane according to claim 1,
wherein the membrane main body comprises:
a layer S comprising a fluorine-containing polymer having a sulfonic acid group;
a layer C comprising a fluorine-containing polymer having a carboxylic acid group; and
a plurality of strengthening materials arranged inside the layer S and functioning as at least one of reinforcement yarn and sacrifice yarn;
wherein A and B, both of which are defined below, satisfy following formula (1):
2.0≤B/A≤5.0 (1)
wherein, when the ion exchange membrane is viewed from a top surface,
A represents an average cross-sectional thickness of the membrane measured in pure water for a region, in which the strengthening materials do not exist, and
B represents an average cross-sectional thickness of the membrane measured in pure water for a region, in which strands of the reinforcement yarn overlap with each other, and for a region, in which the reinforcement yarn overlaps with the sacrifice yarn.

### Claim 5 (depends on 1)

A method for producing the ion exchange membrane according to claim 1, comprising
spraying a coating solution comprising inorganic particles, a binder, and a solvent by a spray system, followed by
drying thereof to form a coating layer on a surface of the membrane main body, wherein an average droplet size during the spraying is 100 μm or less.

### Claim 6 (depends on 5)

The method for producing the ion exchange membrane according to claim 5, wherein a surface temperature of the membrane main body during the drying is 40° C. or more and equal to or less than a boiling point of the solvent.

### Claim 7 (depends on 1)

A method of using the ion exchange membrane according to claim 1, comprising using the ion exchange membrane in an electrolyzer.