JP2004119398A - Catalyst composition for battery, gas diffusion layer, and fuel cell equipped with them - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fuel cell and a jointed body of fuel cells with a high power generation property, of which humidification control can be easily carried out. <P>SOLUTION: The catalyst composition for the fuel cell contains conductive powder including catalyst component and fibrous carbon. The jointed body of fuel cell comprises an electrode having a catalyst layer and a gas diffusion layer on both sides of an electrolyte film, and a layer containing water-repellent resin and fibrous carbon at least at the part of the surface of the gas diffusion layer where the gas diffusion layer contacts with the catalyst layer, and the fuel cell uses the above jointed body of fuel cells. Or, the jointed body of fuel cell comprises an electrode having a catalyst layer and a gas diffusion layer on both sides of an electrolyte film, and a layer containing conductive powder, water-repellent resin and fibrous carbon at least at the part of the surface of the gas diffusion layer where the gas diffusion layer contacts with the catalyst layer, and the fuel cell uses the above jointed body of fuel cells. <P>COPYRIGHT: (C)2004,JPO

Description

The present invention relates to a catalyst composition for a fuel cell, a gas diffusion layer, and a fuel cell including these, and particularly, a catalyst composition useful for forming a catalyst layer of an electrode in a polymer electrolyte fuel cell; an electrolyte membrane, a catalyst The present invention relates to a fuel cell assembly comprising a layer and a gas diffusion layer; and a fuel cell including the same.

Fuel cells are attracting attention as high-efficiency clean power generators that can convert chemical energy directly into electrical energy and take it out.

There are various types of fuel cells, such as alkaline type, phosphoric acid type, molten carbonate type, and solid polymer type, depending on the type of electrolyte used. A polymer electrolyte fuel cell with high power density is expected as a power source for electric vehicles.

For example, FIG. 1 shows a cross-sectional structure of a typical single cell of a polymer electrolyte fuel cell. The basic single cell structure is configured to have an electrode composed of an anode catalyst layer 3 and a cathode catalyst layer 5 with an ion exchange membrane 4 containing appropriate water in the middle. Both the anode catalyst layer 3 and the cathode catalyst layer 5 are made by applying a catalyst that promotes a redox reaction, usually a conductive powder carrying platinum or a platinum alloy powder, and applying the paste to a sheet. .

Outside each of the anode catalyst layer 3 and the cathode catalyst layer 5, a conductive porous anode gas diffusion sheet 2 and a porous cathode gas diffusion sheet 6 for allowing water and gas generated during the reaction to pass therethrough are installed. A reaction gas flow path is provided on the outermost side of the separator plate 1 to form a single cell. A high output battery is configured by stacking the single cells.

In order to advance the reaction of the fuel cell efficiently, the contact efficiency of the three-phase components of the catalyst phase-fuel gas phase or oxidizing gas phase-electrolyte phase in the catalyst layer is high, that is, the three-phase interface is good. is necessary. However, the catalyst layer is usually formed from conductive carbon carrying a platinum catalyst and an ion exchange resin, resulting in “wetting” due to water generated by the reaction, etc., and the platinum surface is covered with water, and oxygen gas or hydrogen gas Since the contact with the catalyst is hindered, the catalytic activity decreases as the “wetting” area increases.

Patent Document 1 discloses an electrode using addition of fine water-repellent fluorine-based binder (for example, polytetrafluoroethylene: hereinafter abbreviated as “PTFE”) fine particles. Although the addition of PTFE can prevent “wetting”, PTFE has no electrical conductivity, and therefore prevents the movement of electrons in the catalyst layer.

Also, in a conventional polymer electrolyte fuel cell, a membrane-electrode assembly is manufactured by sandwiching an ion exchange membrane between two thinned electrodes and bonding them with a hot press. In this method, the spherical catalyst carrier, the ion exchange resin, and PTFE are in close contact with each other due to hot pressing, and a sufficient gas flow path cannot be obtained.

On the other hand, in the polymer electrolyte fuel cell, the dry state of the polymer membrane that is the electrolyte greatly affects the output. Therefore, it is necessary to adjust the humidity from the outside or the inside, and to perform fine moisture control (humidification control) so as not to cause “wetting” to the catalyst and to dry the polymer film.
Japanese Patent Laid-Open No. 7-212324

The first object of the present invention is to suppress the “wetting” in the catalyst layer and not to change or reduce the electrical resistance, and to maintain the gas flow path and to improve the gas permeability. It is an object of the present invention to provide a fuel cell catalyst composition that can improve power generation characteristics and easily perform humidification control. Another object of the present invention is to provide a useful electrode material containing the catalyst composition. Another object of the present invention is to provide a fuel cell provided with a useful electrode material containing the above catalyst composition.

In addition, it is important to remove water generated from the cathode in order to allow the fuel cell reaction to proceed efficiently. Therefore, the porous cathode gas diffusion sheet becomes an important member of the battery.

JP 2001-6699 A discloses a gas diffusion layer in which a paste containing carbon powder and a fluororesin is applied to carbon paper or carbon cloth. At this time, the carbon powder uses a single kind of carbon having a particle size of 0.01 to 0.1 μm. However, the gas diffusion layer having only single seed particles reduces the gaps required for gas diffusion when pressure is applied during battery production.

JP-A-8-7897 describes a gas diffusion layer in which carbon fibers are attached while being intertwined with carbon particles. This gas diffusion layer does not require an electrode base material such as carbon cloth or carbon paper. However, it is difficult to produce a membrane-electrode composite without an electrode substrate. In addition, carbon particles and water-repellent resin are applied to the surface of a substrate made of short carbon fibers, and a catalyst layer is formed on this upper surface, so the contact surface with the catalyst layer becomes carbon particles and water-repellent resin, and gas diffusion Because of this, the air gap is reduced.

The second object of the present invention has a function of not changing or reducing the contact resistance between the gas diffusion layer and the catalyst layer, and a function of securing a gas flow path in a high current density region and improving gas permeability. It is an object of the present invention to provide a fuel cell assembly and a fuel cell that can improve power generation characteristics and can easily perform humidification control.

The above-described object of the present invention is to add fibrous carbon to the interface of the catalyst layer and / or the gas diffusion layer with the catalyst layer, that is, (1) the catalyst layer on both sides of the electrolyte membrane. In a fuel cell having an electrode composed of a gas diffusion layer or a joined body used therefor, (i) the catalyst layer contains a conductive granular material carrying a catalyst component and fibrous carbon, and / or (ii) It has been found that the gas diffusion layer is achieved by a fuel cell having a layer containing a water repellent resin and fibrous carbon on at least a part of the surface of the gas diffusion layer in contact with the catalyst layer.

More specifically, according to the first aspect of the present invention, there are provided a battery in which humidification control is easy and power generation efficiency is improved, and an electrode material and a catalyst composition thereof. That is,
(2) a catalyst composition for a battery comprising a conductive granular material carrying a catalyst component and fibrous carbon;
(3) The catalyst composition for a battery according to (2) above, wherein the catalyst component is a catalyst that promotes a redox reaction in the fuel cell,
(4) The catalyst composition for a battery according to the above (2) or (3), wherein the catalyst component is platinum or a platinum alloy,
(5) The catalyst composition for a battery as described in (2) to (4) above, wherein the conductive powder is conductive carbon black or carbonaceous powder,
(6) The conductive powder particles are at least one selected from the group consisting of furnace black, acetylene black, thermal black, channel black, and ketchin black, as described in (2) to (5) above Battery catalyst composition,
(7) The battery catalyst composition as described in (2) to (6) above, wherein the fibrous carbon is at least one selected from the group consisting of a PAN-based carbon fiber, a pitch-based carbon fiber, and a carbon nanotube. Stuff,
(8) The catalyst composition for batteries according to the above (2) to (6), wherein the fibrous carbon is a vapor growth carbon fiber,
(9) The battery as described in (7) or (8) above, wherein 0.1 to 30% by mass of fibrous carbon is contained in the conductive particles and the fibrous carbon on which the catalyst component is supported. Catalyst composition,
(10) The catalyst composition for a battery according to the above (8) or (9), wherein the vapor-grown carbon fiber is heat-treated at a temperature of 2300 ° C. or higher,
(11) The catalyst composition for a battery according to the above (8) to (10), wherein the vapor-grown carbon fiber contains 0.01 to 10% by mass of boron in the fiber,
(12) The catalyst composition for batteries according to the above (7) to (11), wherein the fibrous carbon has a fiber diameter in the range of 10 to 300 nm,
(13) The catalyst composition for a battery according to the above (7) to (12), wherein the fibrous carbon has a fiber length of 100 μm or less.
(14) An electrode material, wherein a catalyst layer containing the battery catalyst composition according to any one of the above (2) to (13) is formed on a conductive substrate,
(15) The electrode material according to (14) above, wherein the conductive material is a porous conductive substrate, and (16) the polymer electrolyte membrane and the polymer electrolyte membrane sandwiched therebetween In the polymer electrolyte fuel cell comprising a pair of electrodes having a catalyst layer, the catalyst layer is composed of a conductive base material, a catalyst layer including a conductive granular material carrying a catalyst component and fibrous carbon. A polymer electrolyte fuel cell characterized by the above.

Moreover, according to the 2nd side surface of this invention, the function which reduces contact resistance, gas permeability, and a diffusivity are improved, and the fuel cell with high electric power generation efficiency, and its conjugate | zygote are provided. That is,
(17) A fuel cell assembly having electrodes comprising a catalyst layer and a gas diffusion layer on both surfaces of an electrolyte membrane, wherein the gas diffusion layer has water repellency on at least a part of the surface of the gas diffusion layer in contact with the catalyst layer A fuel cell assembly having a layer comprising a resin and fibrous carbon;
(18) The fuel cell assembly according to (17), wherein the gas diffusion layer further comprises conductive particles on at least part of the surface of the gas diffusion layer in contact with the catalyst layer,
(19) The fuel cell assembly according to the above (17) or (18), wherein the gas diffusion layer further includes voids in at least a part of the surface of the gas diffusion layer in contact with the catalyst layer,
(20) The fuel cell according to (19), wherein the void has a cross-sectional area of a void having a pore diameter of 0.1 to 50 μm with respect to a cross-sectional area of all voids in a gas diffusion layer cross section. Zygote,
(21) The fuel cell assembly according to any one of (18) to (20), wherein the conductive particles are conductive carbon black or carbon particles,
(22) The fibrous carbon of the layer containing a water-repellent resin and fibrous carbon is vapor-grown carbon fiber, and the vapor-grown carbon fiber content is 1 to 95% by mass of the entire layer. The fuel cell assembly according to any one of (17) to (21) above,
(23) The fuel cell assembly according to (22) above, wherein the vapor-grown carbon fiber is formed by heat treatment at a temperature of 2000 ° C. or higher.
(24) The fuel cell assembly according to the above (22) or (23), wherein the vapor-grown carbon fiber contains 0.01 to 10% by mass of boron in the fiber.
(25) The fuel cell assembly according to any one of (22) to (24), wherein the vapor-grown carbon fiber is within a range of a fiber diameter of 500 nm or less,
(26) The fuel cell assembly according to (22) to (25), wherein the vapor-grown carbon fiber has a fiber length of 100 μm or less,
(27) The fuel cell assembly according to any one of (17) to (26), wherein the water-repellent resin is a fluororesin.
(28) A step of forming a gas diffusion layer by coating or impregnating a conductive porous substrate with a composition containing conductive particles, a water-repellent resin, and fibrous carbon, and the composition on the gas diffusion layer A fuel cell assembly comprising a step of forming an electrode by forming a catalyst layer containing carbon particles carrying a catalyst on a surface coated or impregnated with a catalyst, and a step of bonding the catalyst layer of the electrode to both surfaces of an electrolyte membrane Manufacturing method,
(29) A fuel cell formed by sandwiching a fuel cell assembly according to (17) to (27) above with a separator, and (30) at least two fuel cells according to (29) above Stacked fuel cells.

According to the first aspect of the present invention, it has the function of suppressing the “wetting” in the catalyst layer, not changing or reducing the electric resistance, and the function of ensuring the gas flow path and improving the gas permeability. Thus, it is possible to obtain a battery catalyst composition, an electrode material, and a fuel cell, which can improve the power generation characteristics and easily perform humidification control. That is, a fuel cell using a battery catalyst composition in which fibrous carbon is added to conductive particles carrying a catalyst for the catalyst layer can improve power generation efficiency and facilitate humidification control. In particular, a battery catalyst composition in which the fibrous carbon is VGCF is suitable. VGCF is desirably mixed in an amount of 0.1 to 30% by mass in the main component of the battery catalyst composition. Further, VGCF contains 0.01 to 10% by mass of boron and graphite at a temperature of 2300 ° C. or higher. When the heat treatment is performed, the conductivity can be further improved.

Further, according to the second aspect of the present invention, the gas diffusion layer having VGCF is added with a function of not changing or reducing the electric resistance and a function of ensuring a gas flow path and improving gas permeability. A fuel cell with improved characteristics can be obtained. In particular, a gas diffusion layer in which the fibrous carbon is VGCF is suitable. VGCF is desirably mixed in the gas diffusion layer in an amount of 1 to 95% by mass, and VGCF contains 0.01 to 10% by mass of boron and is subjected to graphite heat treatment at a temperature of 2000 ° C. or higher. The conductivity can be further improved.

Hereinafter, the present invention will be described in detail. The battery catalyst composition according to the first aspect of the present invention includes a conductive granular material on which a catalyst component is supported, and fibrous carbon.

Examples of the catalyst component used include various catalysts that promote the oxidation-reduction reaction in the fuel cell, such as ruthenium, rhodium, palladium, osmium, iridium, platinum, and alloys thereof. However, the catalyst components are not particularly limited thereto. Absent. Usually, platinum or a platinum alloy is often used.

The conductive particles that are the carrier of the catalyst component are not particularly limited as long as they have conductivity, but those having a specific surface area sufficient to support the catalyst are preferable, for example, carbon black is preferably used. It is done. A fine spherical carbon black having a primary particle diameter of 1 μm or less is particularly preferred. For example, when the catalyst component is platinum, the supported amount is preferably 10 to 60% by mass.

In the first aspect of the present invention, commercially available carbon black having an average primary particle diameter of 1 μm or less can be used. The types of carbon black are oil furnace black obtained by incomplete combustion of aromatic hydrocarbon oil, acetylene black obtained by complete combustion of acetylene and pyrolysis, and natural gas obtained from the production method. There are thermal black, channel black obtained by incomplete combustion of natural gas, etc., and any of them can be used.

In the first aspect of the present invention, it is particularly preferable to use oil furnace black or acetylene black. This is because, as one important factor that determines the performance of carbon black as a conductive material, there is a chain structure (aggregation structure) of primary particles called a structure. The structure of carbon black is generally an agglomerated structure in which microspherical primary particles gather and branch into irregular chains, but the number of primary particles is large, and the connection is branched and complicated (high structure state) ) The higher the conductivity imparting effect. Oil furnace black and acetylene black are preferred because they can be easily obtained in this high structure state.

In the first aspect of the present invention, as the fibrous carbon, what is called PAN-based, pitch-based fibrous carbon, fibrous carbon by a vapor phase method, fibrous carbon having a diameter of about nanometer called nanotube, etc. Everything is usable. However, the pitch-based carbon fiber and the PAN-based carbon fiber have a fiber length longer than 100 μm, and as such, uniform mixing with the catalyst is difficult. Therefore, in consideration of conductivity, it is preferable to use nanotubes or vapor grown carbon fiber (Vapor Growth Carbon Fiber: hereinafter sometimes abbreviated as “VGCF”) by vapor phase method. VGCF with improved electrical conductivity is suitable because it has moderate elasticity.

“VGCF” is produced by gas phase pyrolysis of a gas such as hydrocarbon in the presence of a metal catalyst.

For example, an organic compound such as benzene or toluene is used as a raw material, an organic transition metal compound such as ferrocene or nickelcene is used as a metal catalyst, these are introduced into a high-temperature reactor together with a carrier gas, and VGCF is generated on a substrate. A method (Japanese Patent Laid-Open No. 60-27700), a method of generating VGCF in a floating state (Japanese Patent Laid-Open No. 60-54998), a method of growing VGCF on the reactor wall (Japanese Patent No. 2778434), and the like are known. ing. In Japanese Patent Publication No. 3-64606, metal-containing particles previously supported on a refractory support such as alumina and carbon are brought into contact with a carbon-containing compound at a high temperature to obtain a VGCF having a diameter of 70 nm or less.

Any of these VGCFs manufactured by the above method can be used for the first aspect of the present invention.

In the first aspect of the present invention, a VGCF having a fiber diameter of 300 nm or less and a fiber length of 200 μm or less can be used, but a fiber diameter of 10 to 300 nm and a fiber length of 100 μm or less is preferable. Many VGCFs have a branched structure. In this case, the fiber length is considered to be the length from the branching point of the branch to the tip or the next branching point.

Here, the diameter of VGCF is preferably 10 nm or more, and those having a diameter of less than 10 nm are not practical because they are difficult to industrially mass-produce. Also, the handling of the fine particles increases, and the diameter exceeds 300 nm. The entanglement of the fibers is not sufficient with respect to the particle size and shape of the catalyst, and it is difficult to obtain a conductive effect by addition.

If the fiber length is longer than 100 μm, it is difficult to uniformly mix with the battery catalyst, so that it is difficult to make the catalyst layer thin, and an effective effect cannot be obtained.

In the first aspect of the present invention, the VGCF is preferably heat-treated at a temperature of 2300 ° C. or higher, preferably 2500 to 3500 ° C. in a non-oxidizing atmosphere (argon, helium, nitrogen gas, etc.). It is further advantageous to have a boron compound present in the heat treatment. By allowing the boron compound to coexist, the heat treatment temperature can be lowered by several hundred degrees C. compared to the case where no boron compound is added.

As the boron compound to be coexisted, any substance that generates boron by heating may be used as long as it can obtain a boron content of 0.01 to 10% by mass, preferably 0.1 to 5% by mass after heat treatment. It is not particularly limited, and for example, boron carbide (B ₄ C), boron oxide (B ₂ O ₃ ), boric acid, borate, boron nitride, organic boron compounds, etc., solid, liquid, and even gas Good. In the present invention, it is preferably an inorganic compound from the viewpoints of availability and workability, and boron carbide is particularly preferable.

In addition, since the boron compound may be volatilized depending on the heat treatment conditions, the amount of boron compound added before the heat treatment needs to be larger than the target content. The addition amount of the boron compound is not limited because it depends on the chemical characteristics and physical characteristics of the boron compound to be used, but when boron carbide is used, 0.05 to 10% by mass with respect to VGCF, preferably It is preferable to add in the range of 0.1 to 5% by mass.

In the first aspect of the present invention, the state in which boron is contained in VGCF means that boron is partly dissolved and exists in the surface of carbon fiber, between layers of a carbon sheet laminate, in a hollow portion, or the like. And the boron atom are partially substituted.

When VGCF is heat-treated at 2300 ° C. or higher, not only the conductivity is improved, but also the characteristics such as chemical stability and thermal conductivity are improved. Efficiency (power generation per unit volume) is improved, and durability (ratio of maximum output after continuous use for 1000 hours or more to initial maximum output) is also seen.

In particular, in the VGCF in which the degree of crystallinity is increased by heat treatment at a temperature of 2500 ° C. or higher, the improvement of these battery characteristics is remarkable. Therefore, in the first aspect of the present invention, as a means for increasing the graphitization crystallinity, means for adding boron is used to improve the crystallinity. Any method may be used for mixing the boron compound and VGCF as long as care is taken so that the boron compound and VGCF are mixed uniformly without using a special machine.

The furnace used for heat-treating VGCF can be any furnace such as an Atchison furnace, a high-frequency furnace, a furnace using a graphite heating element, or the like as long as it can be processed at a desired temperature.

In the Atchison furnace, the non-oxidizing atmosphere at the time of heating is obtained by filling the object to be heated in carbon powder. In other furnaces, the atmosphere is replaced with an inert gas such as helium or argon as necessary. This can be achieved.

Further, the heat treatment time is not particularly limited and can be appropriately selected so that all of the objects to be heated reach a predetermined temperature.

The battery catalyst composition according to the first aspect of the present invention is obtained by mixing, as a main component, conductive particles carrying a catalyst component and fibrous carbon. In the 1st side surface of this invention, 0.1-30 mass% of fibrous carbon is mixed in the main component of the catalyst composition for batteries, ie, the electroconductive granular material which carry | supported the catalyst component is 99. It is preferable to mix 9 to 70% by mass and 0.1 to 30% by mass of fibrous carbon. Moreover, in the 1st side surface of this invention, it is more preferable to mix 1-25 mass% of fibrous carbon, and it is preferable to mix especially in the range of 2-20 mass%.

If the amount of fibrous carbon added is less than 0.1% by mass, the effect of addition is difficult to obtain, and if it exceeds 30% by mass, the ratio of the catalyst component, for example, platinum, etc. decreases, resulting in a decrease in battery characteristics. .

In order to mix these, for example, a continuous mixer such as a screw feeder or a batch mixer such as a mixing roll is used to mix uniformly.

In the first aspect of the present invention, additives, water-repellent resins and the like can be added within a range not impairing the effects of the present invention.

A catalyst layer is formed using a catalyst composition adjusted so that the concentration of fibrous carbon falls within the above range.

That is, a mixed solution obtained by adding a solvent to a solution in which the catalyst composition and the ion exchange resin are dissolved is sufficiently stirred with a ball mill, a planetary stirring ball mill, or the like to form a paste. After applying the paste-like mixed liquid onto a conductive substrate such as a carbon sheet or a Teflon sheet, the catalyst layer is formed by drying at a temperature at which the solvent is sufficiently evaporated to obtain an electrode material. In the first aspect of the present invention, the conductive substrate is preferably a porous conductive substrate.

As the ion exchange resin, a perfluorocarbon resin having a sulfonic acid group, a carboxylic acid group or the like as an ion exchange group is preferably used.

In the first aspect of the present invention, an ion exchange membrane is sandwiched between electrode materials, for example, a single cell having a configuration as shown in FIG. 1 can be manufactured, and a fuel cell can be manufactured. A known ion exchange membrane can be used as the ion exchange membrane used here.

In the first aspect of the present invention, as described above, fibrous carbon is mixed into the spherical catalyst-carrying conductive particles, and this makes it possible to create a void suitable for gas diffusion. it can. In addition, this void is not completely crushed even by hot pressing or the like, and since there is fibrous carbon, the void can be maintained in a maintained state, so that a sufficient gas flow path is ensured even after the battery is formed. be able to.

Hereinafter, the second aspect of the present invention will be described in detail.

According to a second aspect of the present invention, there is provided a gas diffusion layer having a layer containing a water repellent resin and fibrous carbon, and further a gas diffusion layer having a layer containing conductive powder particles, a water repellent resin, and fibrous carbon. The present invention relates to a fuel cell assembly.

The conductive powder used in the gas diffusion layer is not particularly limited as long as it is a conductive carbon material, but for example, carbon black is preferably used. Particularly preferred is microspherical carbon black having a primary particle size of 1 μm or less. The secondary particle diameter is preferably about 15 μm or less.

In the second aspect of the present invention, commercially available carbon black having an average primary particle diameter of 1 μm or less can be used. The types of carbon black are oil furnace black obtained by incomplete combustion of aromatic hydrocarbon oil, acetylene black obtained by complete combustion of acetylene and pyrolysis, and natural gas obtained from the production method. There are thermal black, channel black obtained by incomplete combustion of natural gas, etc., and any of them can be used.

In the second aspect of the present invention, it is particularly preferable to use oil furnace black or acetylene black. This is because, as one important factor that determines the performance of carbon black as a conductive material, there is a chain structure (aggregation structure) of primary particles called a structure. The structure of carbon black is generally an agglomerated structure in which microspherical primary particles gather and branch into irregular chains, but the number of primary particles is large, and the connection is branched and complicated (high structure state) ) The higher the conductivity imparting effect. Oil furnace black and acetylene black are preferred because they are in this high structure state.

As the fibrous carbon in the second aspect of the present invention, basically the same carbon fiber as that used in the catalyst layer of the first aspect of the present invention can be used, but there are also differences, and the following points overlap. I will explain.

As the fibrous carbon, those called PAN-based, pitch-based carbon fibers, carbon fibers obtained by a vapor phase method, carbon fibers having a diameter of about nanometers called nanotubes, and the like can be used. However, pitch-based carbon fibers and PAN-based carbon fibers have a long fiber length, and as such, uniform mixing with the catalyst is difficult. Therefore, in view of conductivity, it is preferable to use a nanotube or a vapor grown carbon fiber (hereinafter sometimes abbreviated as VGCF) by a vapor phase method. VGCF with improved properties is suitable because it has moderate elasticity.
VGCF is produced by gas phase pyrolysis of a gas such as hydrocarbon in the presence of a metal catalyst.

For example, an organic compound such as benzene or toluene is used as a raw material, an organic transition metal compound such as ferrocene or nickelcene is used as a metal catalyst, these are introduced into a high-temperature reactor together with a carrier gas, and VGCF is generated on a substrate. A method (Japanese Patent Laid-Open No. 60-27700), a method of generating VGCF in a floating state (Japanese Patent Laid-Open No. 60-54998), a method of growing VGCF on the reactor wall (Japanese Patent No. 2778434), and the like are known. ing. Japanese Patent Publication No. 3-64606 discloses a method of obtaining a VGCF having a diameter of 70 nm or less by bringing metal-containing particles previously supported on a refractory support such as alumina and carbon into contact with a carbon-containing compound at a high temperature. .

Any of these VGCFs manufactured by the above method can be used in the present invention.

In the second aspect of the present invention, a VGCF having a fiber diameter of 500 nm or less and a fiber length of 100 μm or less can be used, but the fiber diameter is 1 to 300 nm, the fiber length is 80 μm or less, and the fiber length is 50 μm or less. Those are preferred. Many VGCFs have a branched structure. In this case, the fiber length is considered to be the length from the branching point of the branch to the tip or the next branching point.

Here, when the fiber length is longer than 100 μm, the secondary particle diameter of the conductive powder is approximately 15 μm or less, and uniform mixing is difficult. Therefore, it is difficult to reduce the thickness of the gas diffusion layer, and an effective effect is obtained. I can't.

In the second aspect of the present invention, VGCF is preferably heat-treated at a temperature of 2000 ° C. or higher, preferably 2500 to 3000 ° C. in a non-oxidizing atmosphere (argon, helium, nitrogen gas, etc.). It is further advantageous to have a boron compound present in the heat treatment. By allowing the boron compound to coexist, the heat treatment temperature can be lowered by several hundred degrees C. compared to the case where no boron compound is added.

As the boron compound to be coexisted, any substance that generates boron by heating may be used as long as it can obtain a boron content of 0.01 to 10% by mass, preferably 0.1 to 5% by mass after heat treatment. It is not particularly limited, and for example, boron carbide (B ₄ C), boron oxide (B ₂ O ₃ ), boric acid, borate, boron nitride, organic boron compounds, etc., solid, liquid, and even gas Good. In the present invention, it is preferably an inorganic compound from the viewpoints of availability and workability, and boron carbide is particularly preferable.

In addition, since the boron compound may be volatilized depending on the heat treatment conditions, the amount of boron compound added before the heat treatment needs to be larger than the target content. The addition amount of the boron compound is not limited because it depends on the chemical characteristics and physical characteristics of the boron compound to be used, but when boron carbide is used, 0.05 to 10% by mass with respect to VGCF, preferably It is preferable to add in the range of 0.1 to 5% by mass. When VGCF is heat-treated at 2000 ° C. or higher, not only the conductivity is improved, but also the characteristics such as chemical stability and thermal conductivity are improved. Efficiency (power generation per unit volume) is improved, and durability (ratio of maximum output after continuous use for 1000 hours or more to initial maximum output) is also seen.

In particular, in the VGCF in which the degree of crystallinity is increased by heat treatment at a temperature of 2500 ° C. or higher, the improvement of these battery characteristics is remarkable. Therefore, in the present invention, as a means for increasing the graphitization crystallinity, a means for adding boron is used to improve the crystallinity. Any method may be used for mixing the boron compound and VGCF as long as care is taken so that the boron compound and VGCF are mixed uniformly without using a special machine.

The furnace used for heat-treating VGCF can be any furnace such as an Atchison furnace, a high-frequency furnace, a furnace using a graphite heating element, or the like as long as it can be processed at a desired temperature.

In the Atchison furnace, the non-oxidizing atmosphere at the time of heating is obtained by filling the object to be heated in carbon powder. In other furnaces, the atmosphere is replaced with an inert gas such as helium or argon as necessary. This can be achieved.

Further, the heat treatment time is not particularly limited and can be appropriately selected so that all of the objects to be heated reach a predetermined temperature.

The water-repellent resin may be any water-repellent resin that has good drainage of this surplus water that reacts with oxygen and protons in the oxygen-side (cathode-side) catalyst layer to generate water and does not hinder gas diffusibility. The surface tension of the water repellent resin is preferably lower than the surface tension of water (about 72 dyn / cm). For example, fluorine resin, polypropylene, and polyethylene can be used, and among these, fluorine resin is preferable. Examples of the fluororesin include polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), and tetrafluoroethylene-hexafluoropropylene copolymer (FEP).

As the conductive porous substrate (gas diffusion sheet), carbon paper, carbon cloth, carbon sheet, and the like can be used, and the carbon sheet disclosed in JP 2000-169253 A can also be used.

The composition containing conductive particles, water-repellent resin and fibrous carbon is a solvent (organic solvent, water, or a mixture thereof) and at least conductive particles, water-repellent resin and fibrous carbon. A paste (slurry) prepared by mixing and is preferably obtained by forming a layer on a conductive porous substrate by applying or impregnating with brushing, spraying or screen printing.

For example, a single cell having a structure as shown in FIG. 1 can be produced by sandwiching an electrolyte membrane (ion exchange membrane) joined with a gas diffusion layer and a catalyst layer according to the second aspect of the present invention, and further a fuel cell is produced. can do. As the ion exchange membrane used here, a known ion exchange membrane can be used, for example, a cation exchange resin membrane, and a perfluorocarbon sulfonic acid membrane is generally used. Specifically, mention may be made of DuPont trade name "Nafion ^TM", manufactured by Asahi Glass Co., Ltd. trade name "Flemion ^TM", Asahi Kasei Corporation, trade name "Aciplex ^TM" and the like.

In the second aspect of the present invention, as described above, the fibrous carbon and the water-repellent resin that also acts as a binder can create voids suitable for gas diffusion by intermingling the fibrous carbon. Moreover, a suitable space | gap can be created by gas diffusion by mixing the spherical carbon granular material which is a conductive granular material, fibrous carbon, and water-repellent resin.

These voids are not completely crushed even by hot pressing, etc., and the voids obtained are maintained because they are in a bridging state where the fibrous carbon contacts each other so as to be entangled with each other or with carbon particles. Can be kept. Therefore, a sufficient gas flow path can be secured even after the battery is formed.

The voids formed by the fibrous carbon include those having a large space, but the space formed by the fibrous carbon and the carbon particles is reduced because the diameter of the carbon particles is generally smaller than the length of the fibrous carbon. It is considered that the distribution of voids (pores) becomes narrower and sharper and the number of voids effective for gas diffusion further increases. When the cross section of the gas diffusion layer is observed with a scanning electron microscope (SEM), the voids having a pore diameter of 0.1 to 50 μm have a cross-sectional area of 40% or more, preferably 50% or more with respect to the entire voids. Effective in improving gas diffusivity in the density region.
Further, as shown in FIG. 6, the internal resistance of the fuel cell largely includes the diffusion resistance component in the electrolyte membrane 11 affected by the electrolyte and the electrolyte, the catalyst layer 10 including the catalyst-supporting carbon particles 12, and the gas diffusion. Contact resistance between the layer 9, the conductive porous substrate (gas diffusion sheet) 8, the conductive powder 14 and the fibrous carbon 13, the conductive substrate 8, the conductive powder 14 and the fibrous carbon 13 is divided into resistance components of the electrode including its own resistance and the like. The bridging effect between the carbon particles and the fibrous carbon reduces the contact resistance between the particles, and the fibrous carbon 13 is exposed on the surface of the gas diffusion layer 9, so that the protruding portion becomes the catalyst layer. Piercing occurs and the contact with the catalyst layer becomes smooth, and the contact resistance is reduced accordingly.

The present invention will be described in more detail below with typical examples. Note that these are merely illustrative examples, and the present invention is not limited thereto.
(Example 1)
A battery catalyst composition was prepared by mixing acetylene black carrying 50% by mass of platinum and a VGCF graphitized product (trade name: VGCF ^™ , manufactured by Showa Denko KK). However, 5 mass% of the VGCF graphitized product was mixed in the main component of the battery catalyst composition. In addition, the VGCF graphitized product manufactured by Showa Denko has a diameter of 100 nm, a bulk density of 0.08 g / cm ³ , and an SEM observation reveals that the fiber length is less than 100 μm and has a branch structure of 90% or more. The form was shown.

1 g of 5% by mass of an ion exchange resin solution (trade name: Nafion ^™ , manufactured by Aldrich) and 5 g of glycerin are added to the produced battery catalyst composition and mixed thoroughly with a ball mill to prepare a mixed solution. did. The mixed solution was applied onto a Teflon ^TM sheet and dried to prepare an electrode catalyst layer formed material (material of the electrode).

Next, a fuel cell was produced using the produced electrode material. That is, the electrode material on which the catalyst layer peeled from the Teflon ^™ sheet was hot-pressed onto an ion exchange membrane (manufactured by DuPont, Nafion ^™ 112 (registered trademark)) to obtain a membrane-electrode assembly. The obtained membrane / electrode assembly is used as a gas diffusion electrode only for the air electrode (cathode), and as the fuel electrode (anode), only platinum-supported carbon is mixed, applied, and pressed in the same manner as described above. A single cell as shown in FIG. 1 was prepared using a separator plate with a groove of 250 mm long × 250 mm wide × 8 mm thick.

The produced single cell was operated under pressure of 0.1 M (mega) Pa through hydrogen and oxidizing gas (air) as fuel gas, and the battery characteristics were evaluated. However, the relationship between the current density and the voltage was examined under the conditions of a temperature of 80 ° C., a hydrogen humidification temperature of the fuel electrode of 80 ° C., and an air humidification temperature of 70 ° C. of the air electrode to evaluate the battery characteristics. The results are shown in FIGS.
(Example 2)
For the production of the membrane / electrode assembly in Example 1, the same as in Example 1 except that the VGCF graphitized product was changed to 0.1% by mass of PAN-based carbon fiber (fiber diameter 5 μm, fiber length 100 μm). A catalyst composition was prepared to obtain an electrode and a single cell. The battery characteristics of the obtained single cell were evaluated. The results are shown in FIG.

From FIG. 2, it was confirmed that Example 1 to which 5 mass% of VGCF was added improved the voltage by about 10% compared with Comparative Example 1 to which VGCF was not added. The measured internal resistance (mΩ · cm ²⁾ at each current density (mA / cm ^2), was dropped about 20mΩ · cm ^2. Moreover, the improvement of the voltage was also confirmed in Example 2 to which the PAN-based carbon fiber was added.
(Example 3)
As the catalyst composition, a membrane / electrode assembly similar to that of Example 1 was prepared using 5% by mass of VGCF containing 3% by mass of boron. The battery characteristics of the obtained single cell were evaluated. The results are shown in FIG.

When VGCF containing 3% by mass of boron was used, the voltage was improved as compared with the VGCF-added system of Example 1. At that time, it was confirmed that the internal resistance was lowered by about 5 mΩ · cm ² .
(Comparative Example 1)
In the production of the battery membrane / electrode assembly in Example 1, a battery catalyst composition was produced in the same manner as in Example 1 except that VGCF was not added to obtain an electrode and a single cell. The battery characteristics of the obtained single cell were evaluated in the same manner as in Example 1. The results are shown in FIGS.
(Example 4)
Using a single cell produced in the same manner as in Example 1, the battery characteristics were evaluated in the same manner as in Example 1. However, the humidification temperature of the air electrode (cathode) was changed to 60 ° C., 66 ° C., and 70 ° C., and the relationship between the current density and the voltage was examined for each. The result is shown in FIG.
(Comparative Example 2)
Using a single cell produced in the same manner as in Comparative Example 1, battery characteristics were evaluated in the same manner as in Example 1. However, the humidification temperature of the air electrode (cathode) was changed to 60 ° C., 66 ° C., and 70 ° C., and the relationship between the current density and the voltage was examined for each. The result is shown in FIG.

From FIG. 2, it was confirmed that Example 1 to which 5 mass% of VGCF was added improved the voltage by about 10% compared with Comparative Example 1 to which VGCF was not added. The measured internal resistance (mΩ · cm ²⁾ at each current density (mA / cm ^2), was dropped about 20mΩ · cm ^2.

When comparing Example 4 and Comparative Example 2 in FIGS. 4 and 5, Example 4 to which 5 mass% of VGCF was added had little voltage fluctuation even when the humidification temperature of the air electrode was changed, and humidification. Although it is easy to control, in Comparative Example 2 in which VGCF was not added, it was found that when the humidification temperature of the air electrode was changed from 60 ° C. to 70 ° C. by 10 ° C., a large voltage drop occurred and the voltage fluctuation was severe.
(Example 5)
Carbon diffusion (made by Showa Cabot, trade name: Vulcan XC-72, average particle size 30 nm), fluororesin PTFE and VGCF graphitized product (made by Showa Denko, trade name: VGCF ^™ ), gas diffusion layer A slurry was prepared. However, the slurry was obtained by mixing Vulcan XC-72: VGCF graphitized product at a mass ratio of 2: 8. On the other hand, 40 mass% of fluorine-based resin was mixed. Further, the VGCF graphitized product has a diameter of 100 nm, a bulk density of 0.08 g / cm ³ , and SEM observation revealed that the fiber length was less than 100 μm and the branched structure form was 90% or more. .

The produced slurry was uniformly applied on the carbon cloth by spraying and then dried to produce a gas diffusion sheet on which a gas diffusion layer was formed.

Next, a slurry obtained by mixing ketjen black carrying 50% by mass of platinum as a catalyst with an ion exchange resin is hot-pressed on an ion exchange membrane (Nafion ^™ 112 (registered trademark) manufactured by DuPont) to form a membrane / electrode assembly. Got. The gas diffusion sheet previously produced for the obtained membrane-electrode assembly was used for the air electrode (cathode), and a porous gas diffusion sheet without a carbon layer was used for the combustion electrode (anode). A single cell as shown in FIG. 1 was produced using the produced electrode and a separator plate with a groove of 250 mm long × 250 mm wide × 2 mm thick.

The produced single cell was operated under pressure of 0.1 M (mega) Pa through hydrogen and oxidizing gas (air) as fuel gas, and the battery characteristics were evaluated. However, the relationship between the current density and the voltage was examined under the conditions of a temperature of 80 ° C., a hydrogen humidification temperature of the fuel electrode of 80 ° C., and an air humidification temperature of 70 ° C. of the air electrode to evaluate the battery characteristics. The result is shown in FIG.
(Example 6)
A slurry for a gas diffusion layer was prepared by mixing fluororesin PTFE and VGCF graphitized product (trade name: VGCF ^™ , manufactured by Showa Denko KK). The fluororesin was mixed at 40% by mass. The slurry was subjected to the evaluation of battery characteristics by forming a gas diffusion layer in the same manner as in Example 5. The result is shown in FIG.
(Comparative Example 3)
In the production of the battery catalyst composition in Example 5, a battery catalyst composition was prepared in the same manner as in Example 5 except that a carbon cloth having no gas diffusion layer was used instead of the gas diffusion sheet on which the gas diffusion layer was formed. An object and a single cell were obtained. About the obtained single cell, it carried out similarly to Example 5, and evaluated the battery characteristic. The result is shown in FIG.

From FIG. 7, it was confirmed that Example 5 in which the conductive carbon particles and the gas diffusion layer added with VGCF were added improved the voltage by about 10% compared with Comparative Example 3 in which VGCF was not added. The measured internal resistance (mΩ · cm ²⁾ at each current density (mA / cm ^2), was dropped about 20mΩ · cm ^2. Furthermore, it was confirmed that the battery characteristics were improved in Example 6 to which the gas diffusion layer produced only by VGCF was added as compared with Comparative Example 3.
(Example 7)
Fluorine resin PTFE and PAN-based carbon fiber (fiber diameter 5 μm, fiber length 100 μm) were mixed to prepare a gas diffusion slurry. The fluororesin was mixed at 40% by mass. The slurry was subjected to the same battery characteristics as in Example 5 by forming a gas diffusion sheet layer. The results are shown in FIG.

It was confirmed that the PAN-based carbon fiber improves the power generation characteristics when VGCF is used for the gas diffusion layer, but the power generation characteristics are inferior to VGCF.
(Example 8)
Using the same production method as in Example 5, the power generation characteristics were examined using VGCF containing 3% by mass of boron in the gas diffusion layer. The results are shown in FIG.

As a result of using boron-containing VGCF with improved electrical conductivity, the internal resistance was reduced by about 5 mΩ · cm ² when VGCF was used as a gas diffusion layer, and the power generation characteristics were improved.

It is sectional drawing which shows typically the basic composition of the single cell of a polymer type fuel cell. It is a graph which shows the relationship between the current density in Example 1, 2 and the comparative example 1, and a voltage. It is a graph which shows the relationship between the current density in Example 1, 3 and the comparative example 1, and a voltage. It is a graph which shows the relationship between the current density and voltage in Example 4. 10 is a graph showing the relationship between current density and voltage in Comparative Example 2. It is a conceptual diagram of a gas diffusion sheet. It is a graph which shows the relationship between the current density in Example 5, 6 and the comparative example 3, and a voltage. It is a graph which shows the relationship between the current density in Example 6, 7 and the comparative example 3, and a voltage. It is a graph which shows the relationship between the current density in Example 5, 8 and the comparative example 3, and a voltage.

Explanation of symbols

1 (with groove) separator plate 2 porous anode gas diffusion sheet 3 anode catalyst layer 4 ion exchange membrane 5 cathode catalyst layer 6 porous cathode gas diffusion sheet 7 joined body 8 gas diffusion sheet (conductive porous substrate)
9 Gas diffusion layer 10 Catalyst layer 11 Electrolyte membrane (ion exchange membrane)
12 Catalyst-supporting carbon particles 13 Fibrous carbon 14 Conductive powder

Claims (15)

A fuel cell assembly comprising an electrode comprising a catalyst layer and a gas diffusion layer on both surfaces of an electrolyte membrane, wherein the gas diffusion layer contacts at least part of the surface of the gas diffusion layer contacting the catalyst layer with a water repellent resin and a fibrous material. A fuel cell assembly comprising a carbon-containing layer. A fuel cell assembly comprising an electrode comprising a catalyst layer and a gas diffusion layer on both surfaces of an electrolyte membrane, wherein the gas diffusion layer contacts at least part of the surface of the gas diffusion layer contacting the catalyst layer with a water repellent resin and a fibrous material. A fuel cell assembly having a layer containing carbon. 3. The fuel cell assembly according to claim 2, wherein the gas diffusion layer further includes conductive particles on at least a part of the surface of the gas diffusion layer in contact with the catalyst layer. 4. The fuel cell assembly according to claim 2, wherein the gas diffusion layer further includes voids in at least a part of the surface of the gas diffusion layer in contact with the catalyst layer. 5. The fuel cell assembly according to claim 4, wherein the voids have a cross-sectional area of voids having a pore diameter of 0.1 to 50 μm with respect to the cross-sectional area of all voids in the gas diffusion layer cross section. The fuel cell assembly according to any one of claims 3 to 5, wherein the conductive particles are conductive carbon black or carbon particles. The layer containing the water-repellent resin and the fibrous carbon is characterized in that the fibrous carbon is a vapor-grown carbon fiber, and the content of the vapor-grown carbon fiber is 1 to 95% by mass of the whole layer. Item 7. The fuel cell assembly according to any one of Items 2 to 6. The fuel cell assembly according to claim 7, wherein the vapor-grown carbon fiber is formed by heat treatment at a temperature of 2000 ° C or higher. The fuel cell assembly according to claim 7 or 8, wherein the vapor-grown carbon fiber contains 0.01 to 10% by mass of boron in the fiber. The fuel cell assembly according to any one of claims 7 to 9, wherein the vapor-grown carbon fiber has a fiber diameter of 500 nm or less. The fuel cell assembly according to any one of claims 7 to 10, wherein the vapor-grown carbon fiber has a fiber length of 100 µm or less. The joined body of a fuel cell according to any one of claims 2 to 11, wherein the water-repellent resin is a fluororesin. A step of applying or impregnating a conductive porous substrate with a composition containing conductive particles, a water repellent resin, and fibrous carbon to form a gas diffusion layer, or applying or applying the composition on the gas diffusion layer A method of manufacturing a fuel cell assembly, comprising: forming an electrode by forming a catalyst layer containing carbon particles carrying a catalyst on the impregnated surface; and bonding the catalyst layer of the electrode to both surfaces of the electrolyte membrane. . A fuel battery cell comprising a separator of the fuel cell assembly according to any one of claims 2 to 12. A fuel cell in which at least two fuel cells according to claim 14 are stacked.

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