Development of a Crosslinked Pore-filling Membrane with an Extremely Low Swelling Ratio and Methanol Crossover for Direct Methanol Fuel Cells

A poly (ether sulphone)-based pore-filling membrane was successfully fabricated and tested against a conventional Nafion-based membrane in direct methanol fuel cells. An amino-containing polymer with a low degree of sulphonation (DS) was synthesized and used as the supporting substrate. The porous substrate was prepared by introducing the porogenic agent (tetrafluoroborate) into the membrane casting solution. The effects of the content of the porogenic agent on the pore morphologies were evaluated using field emission scanning electron microscopy. Then, an epoxy resin was introduced into the porous electrolyte for the first time to minimize the swelling and methanol crossover that resulted from the high degree of sulphonation. In essence, solidification of the amino groups in the substrate results in 3D crosslinking of epoxy resins, which greatly suppresses the swelling and methanol crossover of the composite membranes with enhanced mechanical properties and enhances the thermal and oxidation stability compared to Nafion 117. The resulting composite membrane also shows high proton conductivity that is only slightly lower than that of Nafion 117. However, the selectivity between the proton conductivity and methanol permeability is higher for the composite membranes than that of Nafion 117. The composite membrane also shows a better performance in single cell tests with 10 M methanol.