Abstract: The invention is a method for forming polymer composite films using removable substrates comprising:(a) forming a first dispersion of a first perfluorinated polymer containing sites convertible to ion exchange groups dispersed in a first dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) depositing the first dispersion onto a first removable substrate;(c) removing the first dispersant from the first dispersion, thereby forming a first film;(d) forming a second dispersion of a second perfluorinated polymer containing sites convertible to ion exchange groups and a second dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.

Abstract: The invention is a method for forming polymer composite films using a removable substrate comprising:(a) forming a first dispersion of a first perfluorinated polymer containing sites convertible to ion exchange groups dispersed in a first dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) depositing the first dispersion onto a first removable substrate;(c) heating the first dispersion at a temperature sufficient for form and fuse a first polymer film;(d) forming a second dispersion of a second perfluorinated polymer containing sites convertible to ion exchange groups and a second dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.

Abstract: The invention is a method for forming a solid polymer electrolyte structure comprising:(a.) forming a mixture of a binder and a plurality of catalytically active, electrically conductive particles;(b.) forming the mixture into a particle containing film;(c.) contacting the film with a fluorocarbon membrane in its thermoplastic form;(d.) contacting the particle-containing film with an electrically conductive, hydraulically permeable matrix, thereby forming a laminate having a membrane on one side, a matrix on another side and a plurality of catalytically active particles therebetween; and(e.) applying sufficient pressure to the laminate to embed at least a portion of the matrix into the membrane.

Abstract: The invention is a method for forming a solid polymer electrolyte structure comprising:a. forming a suspension of catalytically active, electrically conductive particles and a liquid such as dibromotetrafluoroethane;b. applying the suspension to at least one side of a fluorocarbon membrane sheet, while said sheet is in its thermoplastic form;c. removing substantially all of the liquid, leaving the particles on the membrane sheet;d. pressing at least a portion of the particles into the membrane sheet;e. contacting the side of the so-treated membrane having the particles on the surface with an electrically conductive, hydraulically permeable matrix;f. subjecting the membrane/matrix combination to a pressure sufficient to embed at least a portion of the matrix into the membrane.

Abstract: The invention is a method for sizing polytetrafluoroethylene fabrics comprising:(a) forming a sizing composition of a perfluorinated polymer containing sites convertible to ion exchange groups and a treating agent having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) contacting the sizing composition with the fibers of a polytetrafluoroethylene fabric; and(c) removing the treating agent from the sizing composition.Particularly preferred as a treating agent is a compound represented by the general formula:XCF.sub.2 -CYZX'wherein:X is selected from the group consisting of F, Cl, Br, and I;X' is selected from the group consisting of Cl, Br, and I;Y and Z are independently selected from the group consisting of H, F, Cl, Br, I and R';R' is selected from the group of perflluoroalkyl radicals and chloroperfluoroalkyl radicals having from 1 to 6 carbon atoms.

Abstract: The invention is a method for forming composite polymer films comprising:(a) forming a dispersion of a first perfluorinated polymer containing sites convertible to ion exchange groups and a dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.97 grams per cubic centimeter; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) forming a first film of the perfluorinated polymer by depositing the dispersion onto a second polymer film containing ion exchange groups or sites convertible to ion exchange groups; and(c) heating the two films for a time and at a temperature sufficient to fuse the two films to each other.Particularly preferred as a dispersant is a compound represented by the general formula:XCF.sub.2 --CYZX'wherein:X is selected from the group consisting of F, Cl.

Abstract: The invention is a method for sizing polyterafluoroethylene fibers, yarns, or threads comprising:(a) contacting polytetrafluoroethylene fibers, yarns, or threads with a sizing composition of a perfluorinated polymer containing sites convertible to ion exchange groups and a treating agent having:a boiling point less than about 110.degree. C.;a density of from about 1.55 to about 2.97 grams per cubic centimeter; anda solubility parameter of from greater than about 7.1 to about 8.2 hildebrands; and(b) removing the treating agent from the sizing composition, thereby depositing the perfluorinated polymer onto the surface of the polytetrafluoroethylene.Particularly preferred as a treating agent is a compound represented by the general formula:XCF.sub.

Abstract: The invention is a method for coating polytetrafluoroethylene fabrics, fibers, yarns, or threads comprising:(a) contacting polytetrafluoroethylene fabrics, fibers, yarns, or threads with a sizing composition of a perfluorinated polymer containing sites convertible to ion exchange groups and a treating agent having:a boiling point less than about 110.degree. C.;a density of from about 1.55 to about 2.97 grams per cubic centimeter; anda solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) removing the treating agent from the sizing composiiton, thereby depositing the perfluorinated polymer onto the surface of the polytetrafluoroethylene; and(c) hydrolyzing the perfluorinated polymer to make it water wettable.Particularly preferred at a treating agent is a compound represented by the general formula:XCF.sub.

Abstract: The invention is a method for forming a solid polymer electrolyte structure comprising:(a) heating a fluorocarbon membrane, while it is in its thermoplastic form, to a temperature at which it softens;(b) contacting a plurality of electrically conductive, catalytically active particles with at least a portion of one face of the membrane, while said membrane is in a softened state;(c) subjecting the membrane/particle combination to a pressure sufficient to embed at least a portion of the particles into the membrane;(d) contacting the particulated membrane with an electrically conductive, hydraulically permeable matrix,(e) subjecting the particulated membrane/matrix combination to a pressure sufficient to embed at least a portion of the matrix into the particulated membrane.

Abstract: The invention is a method for sizing polytetrafluoroethylene fabrics comprising:(a) forming a sizing composition of a perfluorinated polymer containing sites convertible to ion exchange groups and a treating agent having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(b) contacting the sizing composition with the fibers of a polytetrafluoroethylene fabric; and(c) removing the treating agent from the sizing composition.Particularly preferred as a treating agent is a compound represented by the general formula:XCF.sub.2 --CYZX'wherein:X is selected from the group consisting of F, Cl, Br, and I;X' is selected from the group consisting of Cl, Br, and I;Y and Z are independently selected from the group consisting of H, F, Cl, Br, I and R';R' is selected from the group of perfluoroalkyl radicals and chloroperfluoroalkyl radicals having from 1 to 6 carbon atoms.

Abstract: The invention is a method for forming a supported membrane film comprising:(a) at least partially coating a polytetrafluoroethylene fabric with a sizing composition;(b) contacting the coated polytetrafluoroethylene fabric with a membrane film having sites convertible to ion exchange groups; and(c) heating the polytetrafluoroethylene fabric and the membrane film while maintaining the fabric and the film in contact.

Abstract: The invention is a method for forming polymer films having a roughened surface using removable substrates comprising:(a) providing a removable substrate with a roughened surface;(b) forming a dispersion of a perfluorinated polymer containing sites convertible to ion exchange groups in a dispersant having: a boiling point less than about 110.degree. C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands;(c) depositing the dispersion onto the roughened, removable substrate;(d) removing the dispersant from the dispersion; and(e) removing the substrate.Particularly preferred as a dispersant is a compound represented by the general formula:XCF.sub.