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A new, milder sulfonation process was used to produce ion-exchange polymers from a commercial polysulfone (PSU). Membranes obtained from the sulfonated polysulfone are potential substitutes for perfluorosulfonic acid membranes used now in polymer electrolyte fuel cells. Sulfonation levels from 20 to 50% were easily achieved by varying the content of the sulfonating agent and the reaction time. Ion-exchange capacities from 0.5 to 1.2 mmol SO 3 H/g polymer were found via elemental analysis and titration. Proton conductivities between 10 Ϫ6 and 10 Ϫ2 S cm Ϫ1 were measured at room temperature. An increase in intrinsic viscosity with increasing sulfonation degree confirms that the sulfonation process helps to preserve the polymer chain from degradation. Thermal analysis of the sulfonated polysulfone (SPSU) samples reveals higher glass transition temperatures and lower decomposition temperatures with respect to the unsulfonated sample (PSU). Amorphous structures for both PSU and SPSU membranes were detected by X-ray diffraction analysis and differential scanning calorimetry. Preliminary tests in fuel cells have shown encouraging results in terms of cell performance.

A new, milder sulfonation process was used to produce ion‐exchange polymers from a commercial polysulfone (PSU). Membranes obtained from the sulfonated polysulfone are potential substitutes for perfluorosulfonic acid membranes used now in polymer electrolyte fuel cells. Sulfonation levels from 20 to 50% were easily achieved by varying the content of the sulfonating agent and the reaction time. Ion‐exchange capacities from 0.5 to 1.2 mmol SO3H/g polymer were found via elemental analysis and titration. Proton conductivities between 10−6 and 10−2 S cm−1 were measured at room temperature. An increase in intrinsic viscosity with increasing sulfonation degree confirms that the sulfonation process helps to preserve the polymer chain from degradation. Thermal analysis of the sulfonated polysulfone (SPSU) samples reveals higher glass transition temperatures and lower decomposition temperatures with respect to the unsulfonated sample (PSU). Amorphous structures for both PSU and SPSU membranes were detected by X‐ray diffraction analysis and differential scanning calorimetry. Preliminary tests in fuel cells have shown encouraging results in terms of cell performance. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 1250–1257, 2000

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