Ultrathin Alkaline Membranes with Excellent Hardness and Gas Barrier Properties to Achieve Low Ionic Resistance and Mechanical Failure in High Temperature Water Electrolyzers with Low Electrolyte

Alkaline exchange membrane water electrolyzers provide green hydrogen, like liquid alkaline systems, without using the expensive and rare materials that proton exchange membrane electrolyzers require. Although many high performing membranes have been identified for alkaline exchange membrane systems, most lack the mechanical strength and gas barrier properties needed for full integration into electrolyzer stacks and systems, especially when the membranes are thin enough to compete with the acidic counterparts. Ecolectro is developing a new polymer and a novel manufacturing method to produce ultrathin membranes (< 10 microns) using a scalable process. We will combine very thin layers of our previously identified membranes that exhibit excellent chemical stability with new materials that impart mechanical toughness and polymers that prevent dangerous mixing of hydrogen and oxygen. The reduced thickness of the final electrolyte layer will result in exceptionally low ionic resistance, resulting in membranes that surpass commercial membranes. Ecolectro will synthesis new polymer compositions that have either gas barrier properties or mechanical toughness. A new manufacturing method will be demonstrated, that combines the strengths of our exceptional AEMs with the novel materials produced. The final products will be evaluated in electrolysis cells with iridium-free and non-precious metal catalysts at high temperatures and various electrolyte concentrations, validating the performance, mechanical strength and gas barrier properties. The innovations developed herein have significant commercial applications in the hydrogen space in both hydrogen fuel cell and water electrolyzer applications. Scalable methods for thin membrane manufacturing that also result in materials with high performance, mechanical strength and gas barrier properties.