Nafion/clay hybrid membranes with a unique microstructure were synthesized using a fundamentally new approach. The new approach is based on depletion aggregation of suspended particles -a well-known phenomenon in colloids. For certain concentrations of clay and polymer, addition of Nafion solution to clay suspensions in water leads to a gel. Using cryo-TEM we show that the clay particles in the hybrid gels form a network structure with an average cell size in the order of 500 nm. The hybrid gels are subsequently cast to produce hybrid Nafion-clay membranes. Compared to pure Nafion the swelling of the hybrid membranes in water and methanol is dramatically reduced while their selectivity (ratio of conductivity over permeability) increases. The small decrease of ionic conductivity for the hybrid membranes is more than compensated by the large decrease in methanol permeability. Lastly the hybrid membranes are much stiffer and can withstand higher temperatures compared to pure Nafion. Both of these characteristics are highly desirable for use in fuel cell applications, since a) they will allow the use of a thinner membrane circumventing problems associated with the membrane resistance and b) enable high temperature applications.

A series of Nafion-clay nanocomposite membranes were synthesized and characterized. To minimize any adverse effects on ionic conductivity the clay nanoparticles were H + exchanged prior to mixing with Nafion. Well-dispersed, mechanically robust, freestanding nanocomposite membranes were prepared by casting from a water suspension at 180°C under pressure. SAXS profiles reveal a preferential orientation of Nafion aggregates parallel to the membrane surface, or normal plane. This preferred orientation is induced by the platy nature of the clay nanoparticles, which tend to align parallel to the surface of the membrane. The nanocomposite membranes show dramatically reduced methanol permeability, while maintaining high levels of proton conductivity.The hybrid films are much stiffer and can withstand much higher temperatures compared to pure Nafion. The superior thermomechanical, electrochemical and barrier properties of the nanocomposite membranes are of significant interest for direct methanol fuel cell applications.2

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