We developed a block polymer-based synthetic route to sulfonated porous composites (SPCs) with precisely controlled nanopore size. By reducing the pore size to <4 nm and introducing a high density of surface sulfonic acid, the permeation of vanadium ions was effectively suppressed. We employed a polymerization-induced microphase separation (PIMS) process, in which a polyethylene fiber mat impregnated with a liquid polymerization mixture was spontaneously transformed into a fiber-reinforced and cross-linked block polymer membrane. Selective etching and sulfonation then produced the target composite membrane. In a vanadium redox flow battery (VRFB) cell, an SPC with 3.6 nm-sized mesopores, 109 m2 g–1 of specific surface area, and 0.3 mL g–1 of mesoporosity outperformed a Nafion 212 membrane of similar thickness, providing higher proton conductivity and much lower vanadium permeability. Thanks to the composite reinforcement, the membrane demonstrated remarkably enhanced mechanical stability. The SPC membrane could be successfully operated up to 300 cycles. Compared with Nafion 212, the SPC exhibited higher energy efficiencies (EEs) and higher discharge capacity retention. These results suggest the promise of block polymer-based permselective membranes in advanced battery applications.

Recently, because of rapid advances in electrical vehicles, unmanned air vehicles, and humanoid mobile robots, structural energy storage devices with a concurrent capability to store electrochemical energy and to support mechanical loads have been in the spotlight. However, a big hurdle to realizing an integrated electro-chemo-mechanical system is to develop highly compatible active electrodes and structural electrolytes with superior mechanical strength and electrochemical functionality while retaining light weight. We report a load-bearing structural supercapacitor by utilizing a bicontinuous PEO-b-P(S-co-DVB) structural electrolyte and carbon-coated Ni-Co nanowires grown on carbon fiber woven fabric. A liquid polymerization mixture between the electrodes is transformed into a solid-state block copolymer electrolyte, preserving conformal contact with the nanostructured electrode surface. The polymerization-induced microphase separation produces a bicontinuous morphology of cross-linked hard domain and liquid-like conductive domain in the electrode, providing high modulus and high conductivity. The resulting structural supercapacitor is able to operate under tensile and even bending load, suggesting its wide potential applications.