Dickson
Joseph
a,
N. Nambi
Krishnan
a,
Dirk
Henkensmeier
*ab,
Jong Hyun
Jang
ac,
Sun Hee
Choi
a,
Hyoung-Juhn
Kim
a,
Jonghee
Han
a and
Suk Woo
Nam
ac
aFuel Cell Research Center, Korea Institute of Science and Technology, Hwarangro 14-gil5, Seongbuk-gu, Seoul 02792, Republic of Korea. E-mail: henkensmeier@kist.re.kr; Tel: +82 2 958 5298
bUniversity of Science and Technology, 217 Gajungro, Yuseonggu, Daejeon, Republic of Korea
cGreen School, Korea University, Seoul 136-713, Republic of Korea
First published on 5th December 2016
Crosslinked polybenzimidazole (PBI) membranes are most often obtained by reacting the nitrogen atoms of PBI with an alkylating agent. These links can be attacked by nucleophiles at elevated temperatures. To avoid N–CH2-links we introduce a new method to crosslink PBI, starting from ionically crosslinked acid/base blend membranes. By heating them to temperatures above say 200 °C, a Friedel–Crafts reaction between sulfonic acid groups and electron rich phenyl groups covalently crosslinks the acid and base components in the blend by chemically stable aromatic sulfone bonds. According to the literature pure PBI can also be cured and a radical mechanism involving air was suggested. We show that PBI can also be cured in an inert atmosphere. We propose that the thermal curing of pure PBI, which necessitates slightly higher temperatures than blend membranes, proceeds via hydrolysis of imidazole to –COOH and diamine, followed by a Friedel–Crafts reaction of the acid. While crosslinks cannot be directly analysed by nmr or IR, our data support the mentioned mechanism. We show the effect of curing temperature and time on membrane properties like solubility, phosphoric acid uptake and mechanical properties, and test a membrane in a fuel cell, proving that the membranes are gas tight and show a good performance.
A crosslinking method which does not employ nitrogen atoms is the thermally activated Friedel–Crafts reaction between sulfonic acid groups and electron rich, activated phenyl groups, leading to chemically highly stable aromatic sulfones. This type of reaction can be employed without any additive or reagents by simply heating a sulfonated aromatic polymer.24–27 As far as we know, this reaction was never applied to PBI derivatives. In the present contribution, we prepare ionically crosslinked blend membranes of a sulfonated polysulfone (SPAES50), and a commercially available PBI derivative which contains activated phenyl rings in the main chain (PBI–OO). By heating the membranes, we activate the Friedel–Crafts reaction. Due to the large excess of PBI–OO, the sulfonic acid groups preferentially react with PBI–OO, leading to a covalently crosslinked system. The effects of temperature and curing time on the solubility, PA uptake and membrane flexibility and mechanical strength are investigated in this work.
In the following, PA uptake and weight gain during doping are used synonymously. For meta-PBI the acid concentration inside of the doped membranes was found to be around 85% and practically independent of the doping bath concentration.28 Since the water content of the doped acid is very probably not related to the polymer structure, but rather a consequence of hydrogen bonding between PA molecules and water, a concentration of 85% seems to be reasonable also for PBI–OO and blend membranes.
Single cell tests were carried out with a constant gas flow of 82 sccm H2 at the anode and 296 sccm air at the cathode in a fuel cell testing station (CNL, Korea) including mass flow controllers and a temperature control system. All experiments were conducted under ambient pressure at a temperature of 160 °C without any humidification.
The single cell was activated at a constant current density of 0.2 A cm−2. The polarization curve (i–V) was measured using an electronic load (DC-Electronic Load ESL-300Z, ELP) and Fuel Cell Control software V3.00 (CNL, Korea).
PBI–OO is usually synthesized in Eaton's reagent, a mixture of P2O5 and methanesulfoinic acid (MSA). For the preparation of the blend membranes, PBI–OO may need to be washed with a slightly alkaline solution, to remove trace amounts of MSA (Fig. 2). Alternatively, the polymer can also be re-precipitated from NMP into water.
Fig. 2 TGA curves of PBI–OO. Top: as received, with ca. 5 wt% methanesulfonic acid and bottom: after washing. |
First crosslinking experiments were done by heating membranes for 8 hours in an argon atmosphere. To evaluate if the reaction parameters lead to covalent crosslinking, the membrane samples were immersed in DMAc at 80 °C for 15 hours (Fig. 4). Another important parameter is the membrane flexibility, which was assessed qualitatively by bending samples. As shown in Table 1, if the temperature chosen is too high, membranes become brittle. It can also be seen that both PBI–OO and ionically crosslinked blend membranes of 80% PBI–OO and 20% SPAES50 are soluble without heat treatment, and that a temperature of about 180–240 °C is necessary to obtain insoluble, apparently covalently crosslinked, membranes. It is also possible to crosslink pure PBI–OO.1,13,23 The mechanism for this is not clear, but may involve carboxylic acid groups which are either present as unreacted end groups or available by hydrolytic degradation of imidazole rings, and react in a Friedel–Crafts reaction with a phenyl ring (Fig. 5). Hydrolysis of polybenzimidazole under alkaline conditions is a very fast process,21,29 but also hydrolysis of polybenzoxazole under neutral conditions is known, and discussed as a failure mode in bullet proof vests.30 Therefore, to assume hydrolysis of PBI as a first reaction step during crosslinking is not unreasonable. Alternative mechanisms could involve formation of amides, or radical mechanisms in the presence of air, leading also to the formation of carbonyl groups.23 Radical crosslinking in the absence of air is not expected, because the traditional synthesis of linear PBI involves heating to 260–400 °C for several hours under high vacuum and does not lead to crosslinked materials.1 Therefore, the presence of some water traces in the membrane seems to be vital. The finding that thermal crosslinking of washed, acid free PBI–OO in an inert atmosphere affords higher reaction temperatures than acid containing PBI–OO supports a hydrolysis-Friedel–Crafts reaction mechanism, which is acid catalysed. For crosslinking blend membranes in an argon atmosphere during a reaction time of 8 hours, temperatures of about 240–280 °C seem to be good, leading to covalently crosslinked, flexible membranes. For acid free PBI–OO, higher temperatures around 300 °C seem to be needed, risking brittleness. This brittleness, beginning at temperatures above 240 °C, could be a direct result of hydrolysis induced chain scission.
Fig. 4 PBI–OO (washed) membrane samples immersed in DMAc at 80 °C for 15 h (as in Table 1, 2nd data column). |
Solubility in DMAc at 80 °C for 15 h | Flexibility | |||||||
---|---|---|---|---|---|---|---|---|
PBI–OO, as received | PBI–OO, washed | Blend, SPAES in K+ form | Blend, SPAES in H+ form | PBI–OO, as received | PBI–OO, washed | Blend, SPAES in K+ form | Blend, SPAES in H+ form | |
a +: soluble, ±: gelation and/or partially soluble, −: insoluble, O: flexible, ✗: brittle, n/a: not assessed. | ||||||||
Untreated | + | + | + | + | O | O | O | O |
160 °C | + | + | + | n/a | O | O | n/a | n/a |
180 °C | ± | + | − | n/a | O | O | n/a | n/a |
200 °C | + | + | − | ± | O | O | O | O |
220 °C | − | + | − | ± | O | O | O | O |
240 °C | − | ± | − | − | ✗ | O | O | O |
260 °C | − | ± | − | − | ✗ | O | O | O |
280 °C | − | ± | − | − | ✗ | O | O | O |
300 °C | − | − | − | n/a | ✗ | ✗ | O | n/a |
320 °C | − | − | − | n/a | ✗ | ✗ | ✗ | n/a |
According to the van't Hoff rule, reactions should proceed at least 2 times faster when the temperature is increased by 10 °C. As shown in Table 2, washed PBI–OO membranes are brittle after 8 hours at 300 °C. Shortening the reaction time to 1–4 hours allows obtaining flexible, crosslinked membranes. Only at a reaction time of 30 minutes do the membrane samples start to be partially soluble, and a slight discoloration of the solution in which the membrane is immersed can be observed (Fig. 6). Very probably, an increased reaction temperature will allow to further reduce the reaction time, rendering the process also attractive for industrial production processes.
Solubility in DMAc at 80 °C for 15 h | Flexibility | |
---|---|---|
a ±: partially soluble, −: insoluble, O: flexible, ✗: brittle. | ||
0.5 h | ± | O |
1 h | − | O |
2 h | − | O |
4 h | − | O |
8 h | − | ✗ |
Fig. 6 PBI–OO (washed) membrane samples immersed in DMAc at 80 °C for 15 h (as in Table 2, 1st data column). |
For the application, a most important parameter is the phosphoric acid (PA) uptake of membranes, which highly correlates with the proton conductivity, and inversely correlates with the tensile strength and Young's modulus of the doped membranes. For a 80:20 blend membrane containing SPAES50 in the salt form, the PA content was analysed (Fig. 7). It can be seen that the PA uptake follows the expected trend: higher reaction temperature led to a higher degree of crosslinking, limiting the swelling of the membrane and thus the PA uptake. An interesting feature of the doping curves in Fig. 7 is the doping behavior of the pure PBI–OO membrane, which shows a local minimum at around 48 hours. PBI–OO is fully soluble in PA at temperatures larger than 160–200 °C, and it makes sense to assume also a slight solubility at room temperature. And indeed, all doping solutions developed a slight discoloration. Therefore, the curves in Fig. 7 represent two simultaneous processes: polymer dissolution, reducing the weight, and PA absorption, increasing the weight.
Fig. 7 PA uptake under ambient conditions for a 80:20 blend of PBI–OO and SPAES50 (K+ form), heated in an argon atmosphere for 8 hours. |
Fig. 8 Photographic images of PBI–OO blend membranes with (1) 0, (2) 2.5, (3) 5, (4) 10 and (5) 20 wt% SPAES50, (a) before and (b) after PA doping at 80 °C for 24 h. |
Table 3 summarizes experimental parameters and the resulting material properties for different materials and processes. Entries 9/10 and 14/15 each represent nominally same batches, to test the reproducibility, which is in general given, with most values being within each other's error range. If we assume that insufficient crosslinking (too low curing temperatures) and too harsh curing conditions (degradative reactions) can lead to increased variation in the PA uptake, it is interesting to analyse the standard deviation of the PA uptake. Only in 6 cases the standard deviation is >10% of the PA uptake. In the case of entries 3–5 (PBI–OO), the reason could be the low, insufficient curing temperature, while in the case of entry 18 (blend), the short curing time. As already concluded from Table 1, pure PBI–OO seems to need a higher curing temperature than blend membranes. When the curing temperature for PBI–OO is increased from 300 to 320 °C, the PA uptake shows a standard deviation of only 6% (entry 6). For entry 17 (blend), the reason may be that degradation already sets in when the material is cured at 320 °C for 2.5 hours. In conclusion, the curing temperature and time needs to be optimised for each material, considering parameters like flexibility, solubility, PA uptake, PA uptake variation between samples, conductivity and the mechanical properties.
Sample number | Polymer blend composition PBI–OO:SES | Heat treatment conditions (temperature, gas, time) | PA doping conditions | PA uptake (wt%) | Tensile strength (MPa) | Young modulus (MPa) | Elongation at break (%) | Performance indicator |
---|---|---|---|---|---|---|---|---|
1 | 100:0 | No heat treatment | 80 °C 48 h | Excessive swelling | — | — | — | — |
2 | 100:0 | No heat treatment | 30 °C 48 h | 361 ± 17 | 5.93 ± 1.3 | 78.14 ± 12 | 102 ± 21 | 4.3 |
3 | 100:0 | 300 °C/Ar/2.5 h (metal plates) | 90 °C 48 h | 582 ± 118 | 2.32 ± 0.3 | 75.23 ± 9 | 8 ± 2 | 2.7 |
4 | 100:0 | 300 °C/N2/2.5 h | 90 °C 48 h | 903 ± 357 | 2.96 ± 0.8 | 29.27 ± 9 | 52 ± 35 | 5.3 |
5 | 100:0 | 300 °C/N2/2.5 h | 80 °C 48 h | 649 ± 142 | 4.68 ± 2.3 | 65.03 ± 19 | 65 ± 26 | 6.1 |
6 | 100:0 | 320 °C/N2/2.5 h | 80 °C 24 h | 505 ± 30 | 6.4 ± 2.4 | 84.02 ± 23 | 28 ± 7 | 6.5 |
7 | 97.5:2.5 | 290 °C/N2/2.5 h | 80 °C 48 h | 459 ± 39 | 5.35 ± 0.90 | 104.27 ± 36 | 39 ± 6 | 4.9 |
8 | 95:5 | No heat treatment | 80 °C 24 h | 419 ± 65 | 3.4 ± 0.6 | 85.49 ± 11 | 15 ± 7 | 2.8 |
9 | 95:5 | 280 °C/N2/2.5 h | 90 °C 48 h | 329 ± 10 | 10.05 ± 3 | 151.40 ± 8 | 55 ± 25 | 6.6 |
10 | 95:5 | 280 °C/N2/2.5 h | 90 °C 48 h | 325 ± 19 | 8.57 ± 1.7 | 168.40 ± 10 | 30 ± 21 | 5.6 |
11 | 95:5 | 280 °C/N2/2.5 h | 80 °C 48 h | 494 ± 26 | 4.97 ± 0.84 | 75.94 ± 4 | 33 ± 30 | 4.9 |
12 | 95:5 | 320 °C/N2/0.5 h | 80 °C 24 h | 445 ± 3 | 8.6 ± 0.7 | 70.06 ± 13 | 20 ± 2 | 7.7 |
13 | 90:10 | No heat treatment | 80 °C 24 h | 380 ± 32 | 4.33 ± 0.83 | 57.03 ± 15 | 60 ± 16 | 3.3 |
14 | 90:10 | 260 °C/N2/2.5 h | 90 °C 48 h | 385 ± 10 | 9.10 ± 0.24 | 73.65 ± 19 | 113 ± 6 | 7.0 |
15 | 90:10 | 260 °C/N2/2.5 h | 90 °C 48 h | 400 ± 33 | 5.84 ± 1.74 | 95.16 ± 34 | 36 ± 27 | 4.7 |
16 | 90:10 | 260 °C/N2/2.5 h | 80 °C 48 h | 400 ± 29 | 5.86 ± 0.94 | 99.48 ± 28 | 62 ± 30 | 4.7 |
17 | 90:10 | 320 °C/N2/2.5 h | 80 °C 24 h | 454 ± 57 | 7.7 ± 1.8 | 85.25 ± 19 | 15 ± 9 | 7.0 |
18 | 80:20 | 220 °C/N2/2.5 h | 90 °C 48 h | 313 ± 31 | 7.13 ± 0.24 | 106.16 ± 49 | 44 ± 24 | 4.5 |
In order to describe the trade-off relationship between the PA uptake and tensile strength, which should be pushed to overall higher values for good materials, we introduce a “performance indicator” in Table 3. It is calculated as
Performance indicator = (PA uptake) × (tensile strength) × 2/1000. |
Roughly, materials with an indicator below 3.5 are rather bad materials, values <5 indicate intermediate materials, and >5 indicates potentially good materials. This is a very crude approach to categorize the materials as it does not include important properties like the conductivity and probably does not weigh the available data correctly. However, when the tensile strength data from Table 3 are plotted logarithmically against the PA uptake, the materials from Table 3 seem to fall into 3 categories, which correlate with the performance indicator (Fig. 9). It is seen that blend membranes without heat treatment and the PBI–OO membrane treated between metal plates have a disadvantageous relationship between the PA uptake and tensile strength (red diamonds). Untreated PBI–OO and some blend membranes are in the middle range (yellow triangles). All membranes with a performance indicator >5 fall into the best category (green squares), and are heat treated. For comparison, commercial meta-PBI shows indicator values between 4.2 and 5.6 in the literature.31,32 Future good materials should provide values above the green line. An alternative to the tensile strength based performance indicator could be a performance indicator which is calculated in the same way but based on the Young modulus. In that case, materials with an indicator above 80 may be considered as good, and entries 5, 6, 9 and 10 would be considered as good materials according to both performance indicators.
The sample with the highest performance indicator was sample 12. Therefore, it was tested in the fuel cell (Fig. 10). The performance is comparable to that of cells using the standard material meta-PBI, with a peak power density of ca. 200 mW cm−2.33 The test shows clearly that the membranes are gas tight (high open circuit voltage) and can operate in a fuel cell. By using an improved cell design, it will be possible to increase the performance. Details will be shown in another paper.
Fig. 10 Polarization curves of the membrane (sample number 12 from Table 3, thickness after doping = 130 μm) at 160 °C, cell area 7.84 cm2, non-humidified, after 24 h activation at 160 °C, 0.2 A cm−2. |
When the mechanical properties are plotted logarithmically against the PA uptake, a linear trend can be observed. By crosslinking it is possible to shift this trade-off relationship towards more advantageous values. By a fuel cell test, we show for the first time that sulfone crosslinked blend membranes can be used in fuel cells. A more detailed analysis is ongoing and will be published later.
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