JP2004319433A - Method of forming functional porous layer, method of manufacturing fuel cell, electronic equipment, and automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of efficiently forming a functional porous layer including a functional material supported by a porous material so that the present amount of the functional material has a desired concentration distribution in the depth direction, a method of manufacturing a fuel cell in which this method is applied to formation of a reaction layer, and electronic equipment and an automobile equipped with a fuel cell obtained by this manufacturing method as power supply sources. <P>SOLUTION: This method of forming the functional porous layer including the functional material supported by the porous material comprises applying a solution or dispersed solution of two or more functional materials differed in surface tension to a porous layer, and controlling the penetration of the functional materials to the depth direction of the porous layer by the difference in surface tension to form the functional porous layer. The fuel cell is manufactured by applying this method to form the reaction layer. The electronic equipment and automobile are equipped with this fuel cell as power supplying sources. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention provides a method for forming a functional porous layer in which a functional material is supported so that the amount of the functional material changes in the depth direction of the porous layer, and the method is applied to the formation of a reaction layer. The present invention relates to a method for manufacturing a fuel cell, and an electronic device and a vehicle including the fuel cell obtained by the method as a power supply source.

  Conventionally, there is a fuel cell including an electrolyte membrane, an electrode (anode) disposed on one side of the electrolyte membrane, an electrode (cathode) disposed on the other side of the electrolyte membrane, and the like. For example, in a solid polymer electrolyte fuel cell in which the electrolyte membrane is a solid polymer electrolyte membrane, a reaction that converts hydrogen into hydrogen ions and electrons is performed on the anode side, electrons flow to the cathode side, and hydrogen ions flow to the cathode side. After moving in the electrolyte membrane, a reaction for generating water from oxygen gas, hydrogen ions and electrons is performed on the cathode side.

  In such a solid oxide fuel cell, each electrode is usually composed of a reaction layer made of metal fine particles which is a reaction catalyst of a reaction gas, a gas diffusion layer made of carbon fine particles on the substrate side of the reaction layer, and a gas diffusion layer. And a current collecting layer made of a conductive substance on the substrate side of the layer. In one substrate, the hydrogen gas uniformly diffused through the gap between the carbon fine particles constituting the gas diffusion layer reacts in the reaction layer to become electrons and hydrogen ions. The generated electrons are collected in the current collecting layer, and the electrons flow in the current collecting layer of the other substrate. Hydrogen ions move to the reaction layer of the second substrate via the polymer electrolyte membrane, and a reaction is performed to generate water from electrons and oxygen gas flowing from the current collection layer.

  In such a fuel cell, as a method for forming a reaction layer, for example, a paste for forming an electrode catalyst layer prepared by mixing (a) a catalyst-supporting carbon with a polymer electrolyte solution and an organic solvent is used as a transfer base material (polystyrene). A method of transferring a catalyst layer (reaction layer) to an electrolyte membrane by coating the coating on a tetrafluoroethylene sheet), drying it, thermocompression bonding it to an electrolyte membrane, and then peeling off a transfer substrate (Patent Document 1); b) A method is known in which an electrolyte solution of carbon particles carrying a solid catalyst is applied on a carbon layer used as an electrode by using a spray and then the solvent is volatilized (Patent Document 2).

  However, these methods involve a large number of steps and are complicated, and furthermore, it is difficult to uniformly apply a catalyst or to accurately apply a predetermined amount of a catalyst to a predetermined position. However, there has been a problem that the production cost is increased due to a decrease in the characteristics (output density) of the catalyst and an increase in the use amount of an expensive catalyst such as platinum.

JP-A-8-88008 JP-A-2002-298860

  The present invention provides a method for efficiently forming a functional porous layer in which a functional material is supported on a porous substance, so that the amount of the functional material has a desired concentration distribution in the depth direction. It is an object of the present invention to provide a method of manufacturing a fuel cell in which this method is applied to the formation of a reaction layer, and an electronic device and a vehicle equipped with the fuel cell obtained by this method as a power supply source.

  The present inventors have conducted intensive studies to solve the above-described problems, and as a result, applied a solution or dispersion of a plurality of types of functional materials having different surface tensions to the porous layer, and due to the difference in the surface tensions, The ability to control the permeation of the solution or dispersion of the material in the depth direction of the porous layer, and by applying this method to the formation of the reaction layer of the fuel cell, the amount of the metal fine particles is reduced to the carbon-based material particles. The present inventors have found that a reaction layer in which metal fine particles are supported by carbon-based material particles can be efficiently formed so as to change in the depth direction of a porous layer made of, and the present invention has been completed.

  Thus, according to the first aspect of the present invention, there is provided a method for forming a functional porous layer in which a functional material is supported on a porous substance, wherein a plurality of types of solutions or dispersions of functional materials having different surface tensions are provided. To a porous layer, and controlling the penetration of the functional material in the depth direction of the porous layer by the difference in the surface tension, to provide a method for forming a functional porous layer. You.

  In the method for forming a functional porous layer of the present invention, the functional porous layer is applied with a plurality of types of functional material solutions or dispersions having different surface tensions on the porous layer, and the solution or dispersion is performed. It is preferably formed by removing the solvent contained in the liquid.

  In the method for forming a functional porous layer according to the present invention, the functional porous material in which the functional material is supported on the porous substance so that the amount of the functional material changes in the depth direction of the porous layer. It is preferable to form a layer.

  In the method for forming a functional porous layer according to the present invention, a step of applying a solution or dispersion of a functional material to the porous layer and impregnating the porous layer with the solution or dispersion of the functional material is performed on the surface. It is preferable to repeat a plurality of times using a solution or dispersion of the functional material having a different tension, and it is more preferable to change the concentration of the solution or dispersion of the functional material each time.

  In the method for forming a functional porous layer of the present invention, a solution or dispersion of the first functional material is applied to the porous layer, and the solution or dispersion of the first functional material is applied to the porous layer. After the impregnation, a solution or dispersion of a second functional material having a surface tension greater than the solution or dispersion of the first functional material is applied to the porous layer, and the second functional material is It is more preferable to impregnate a solution or dispersion of the above.

  In the method for forming a functional porous layer according to the present invention, as the solution or dispersion of the functional materials having different surface tensions, those prepared by dissolving or dispersing the functional materials in different types of solvents are used. Preferably, as the solution or dispersion of the functional material, fine particles of one or more metals selected from the group consisting of platinum, rhodium, ruthenium, iridium, palladium, osmium and an alloy of two or more thereof, or It is preferable to use a solution or dispersion of the metal compound.

  In the method for forming a functional porous layer of the present invention, it is preferable that the porous layer is a porous layer made of carbon-based material particles. Further, the functional porous layer may be made of a carbon-based material in which fine particles of one or more metals selected from the group consisting of platinum, rhodium, ruthenium, iridium, palladium, osmium and alloys of two or more thereof are used. It is preferable that the fuel is supported by particles, and the fuel is formed by forming a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer in this order. More preferably, it is at least one of the first reaction layer and the second reaction layer of the battery.

  In the method for forming a functional porous layer according to the present invention, it is preferable that the application of the solution or dispersion of the functional material is performed using a discharge device.

  According to a second aspect of the present invention, there is provided a fuel cell manufacturing method for forming a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer, At least one of the first reaction layer and the second reaction layer is applied with a solution or dispersion of a plurality of types of reaction layer forming materials having different surface tensions to a porous layer made of carbon-based material particles, Alternatively, there is provided a method for manufacturing a fuel cell, wherein the method is formed by removing a solvent contained in a dispersion.

  In the method for manufacturing a fuel cell according to the present invention, at least one of the first reaction layer and the second reaction layer is formed by abundance of a reaction layer forming material in a depth direction of a porous layer made of carbon-based particles. It is preferable that the material for forming a reaction layer forms a reaction layer in which the material for a reaction layer is supported on carbon-based material particles so that the reaction layer changes.

  In the method for manufacturing a fuel cell according to the present invention, at least one of the first reaction layer and the second reaction layer is coated with a solution or dispersion of a material for forming a reaction layer on a porous layer made of carbon-based material particles. The step of impregnating the porous layer with the solution or dispersion of the reaction layer forming material is preferably performed by repeating a plurality of times using a solution or dispersion of the reaction layer forming material having a different surface tension. .

  In the method for manufacturing a fuel cell according to the present invention, at least one of the first reaction layer and the second reaction layer is formed by using a solution or dispersion of the first reaction layer forming material as a porous material comprising carbon-based material particles. After applying to a layer and impregnating the solution or dispersion of the first reaction layer forming material into a porous layer composed of carbon-based material particles, the solution or dispersion of the first reaction layer forming material is used. A solution or dispersion of the second reaction layer forming material having a large surface tension is applied to the porous layer composed of the carbon-based material particles, and impregnated with the solution or dispersion of the second reaction layer forming material. It is more preferable to form them.

  In the fuel cell manufacturing method of the present invention, as the solution or dispersion of the reaction layer forming materials having different surface tensions, those prepared by dissolving or dispersing the reaction layer forming materials in different kinds of solvents are used. Is preferred.

  In the method for manufacturing a fuel cell according to the present invention, at least one of the first reaction layer and the second reaction layer is coated with carbon-based material particles on a first current collecting layer or a second current collecting layer. To form a porous layer composed of carbon-based material particles, and then apply a solution or dispersion of a plurality of types of reaction layer forming materials having different surface tensions to the porous layer composed of the carbon-based material particles. It is preferable to form by removing the solvent contained in the solution or dispersion.

  In the method for manufacturing a fuel cell according to the present invention, it is preferable that the solution or the dispersion of the material for forming a reaction layer is applied using a discharge device.

  In the method for manufacturing a fuel cell according to the present invention, at least one of the first reaction layer and the second reaction layer includes metal fine particles supported on carbon-based material particles, and the abundance of the metal fine particles is It is preferable that the reaction layer is formed to be higher on the electrolyte membrane side than on the current collection layer side.

  According to a third aspect of the present invention, there is provided an electronic apparatus including a fuel cell manufactured by the manufacturing method of the present invention as a power supply source.

  According to a fourth aspect of the present invention, there is provided an automobile including a fuel cell manufactured by the manufacturing method of the present invention as a power supply source.

  According to the method for forming a functional porous layer of the present invention, the surface tension is different, by applying a solution or dispersion containing a plurality of types of functional materials to the porous layer, by the difference in surface tension, the function Since the penetration of the functional material into the porous layer in the depth direction can be easily controlled, the functional porous layer in which the functional material is distributed so as to change in the depth direction can be easily formed. can do.

  In the method for forming a functional porous layer of the present invention, after applying a solution or dispersion of a functional material having a relatively small surface tension, applying a solution or dispersion of a functional material having a relatively large surface tension. In this case, the functional porous layer in which the functional material is distributed so as to be continuously reduced in the depth direction can be easily formed.

  In the method for forming a functional porous layer of the present invention, when a solution or a dispersion of functional materials having different surface tensions is prepared by dissolving or dispersing the same functional material in different types of solvents. Can easily form a functional porous layer in which the same functional material is distributed so as to change in the depth direction, preferably to decrease continuously in the depth direction.

  In the method for forming a functional porous layer of the present invention, a step of applying a solution or dispersion of a functional material having a different surface tension to the porous layer and repeating the step of impregnating the porous material with the functional material, that is, The surface tension of the solution or dispersion of the functional material to be used is set to an arbitrary value, the solution or dispersion of the functional material having a different surface tension is arbitrarily combined, or the application amount of the solution or dispersion of the functional material is adjusted. By arbitrarily setting, a functional porous layer having a desired functional material concentration distribution (existence distribution) in the depth direction can be easily formed.

  In the method for forming a functional porous layer of the present invention, the porous layer is a porous layer made of carbon-based material particles, and the functional porous layer is formed of platinum, rhodium, ruthenium, iridium, palladium, osmium and When one or two or more kinds of metal fine particles selected from the group consisting of these two or more kinds of alloys are used, the metal fine particles change in the depth direction in the porous layer made of carbon-based material particles. In addition, it is possible to easily form a functional porous layer in which metal fine particles are preferably continuously distributed in the depth direction and are supported by porous carbon-based material particles.

  The method for forming a functional porous layer according to the present invention provides a fuel in which a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer are formed in this order. It can be preferably applied as a method for forming the first reaction layer or the second reaction layer of a battery.

  Further, in the method for forming a functional porous layer of the present invention, when applying a solution or dispersion of a functional material using a discharge device, the functional material can be accurately applied to a predetermined position. Therefore, a functional porous layer having a profile as designed can be easily formed. In addition, since the solution or dispersion of the functional material can be applied to a predetermined position as needed, unnecessary functional material is not applied, and the amount of the functional material used can be reduced.

  ADVANTAGE OF THE INVENTION According to the manufacturing method of the fuel cell of this invention, the fuel cell which has the reaction layer which the material for reaction layer formation distributes so that it changes with respect to a depth direction can be manufactured easily and efficiently.

  In the method for producing a fuel cell according to the present invention, the surface tension is relatively small, and after applying a solution or dispersion of the reaction layer forming material, the surface tension is relatively large, and the reaction layer forming material solution or dispersion is applied. When the liquid is applied, it is possible to easily and efficiently manufacture a fuel cell having a reaction layer in which the reaction layer forming material is continuously reduced in the depth direction.

  In the method of manufacturing a fuel cell according to the present invention, when the application of the reaction layer forming material is performed using a discharge device, the concentration distribution of the desired reaction layer forming material in the depth direction (existence distribution) ) Can be efficiently formed. Also. Compared with the case where a conventional reaction layer forming material is solid-coated to form a reaction layer, the amount of expensive reaction layer forming material used is reduced. Therefore, a fuel cell with high output can be manufactured at low cost.

  Further, according to the method for manufacturing a fuel cell of the present invention, at least one of the first reaction layer and the second reaction layer has metal fine particles supported on carbon material particles, and the amount of the metal fine particles is reduced. It is possible to efficiently form the reaction layer so that it is higher on the electrolyte membrane side than on the current collection layer side.

  The fuel cell manufactured by the manufacturing method of the present invention has a low cost, a high power density, and excellent characteristics because the reaction layer having a uniform and desired amount of metal fine particles is efficiently formed. ing.

  The fuel cell obtained by the manufacturing method of the present invention is useful as a power supply source for electronic devices and automobiles.

  An electronic device according to the present invention includes a fuel cell manufactured by the manufacturing method according to the present invention as a power supply source. ADVANTAGE OF THE INVENTION According to the electronic device of this invention, the clean energy which considered the global environment appropriately can be provided as a power supply source.

  Further, an automobile according to the present invention includes a fuel cell manufactured by the manufacturing method according to the present invention as a power supply source. ADVANTAGE OF THE INVENTION According to the vehicle of this invention, the clean energy which considered the global environment appropriately can be provided as a power supply source.

  Hereinafter, a method for forming a functional porous layer, a method for manufacturing a fuel cell, and an electronic device and an automobile including the fuel cell of the present invention will be described in detail.

1) Method for Forming Functional Porous Layer The method for forming a functional porous layer of the present invention is a method for forming a functional porous layer in which a functional material is supported on a porous substance, and has a surface tension. A plurality of different types of solutions or dispersions of functional materials are applied to the porous layer, and the difference in the surface tension is used to control the penetration of the functional material in the depth direction of the porous layer. And

  In the present invention, the functional porous layer refers to a porous layer in which a functional material is carried (or adsorbed) on a porous substance in the porous layer. Further, the method for forming a functional porous layer of the present invention is a method for forming a porous layer in which a functional material is present in a predetermined concentration distribution in a depth direction in a porous layer. This also includes the case where a layer made of a functional material is formed on the surface of the material layer.

  Although the pore diameter of the porous layer used in the present invention is not particularly limited, it is usually several tens nm to several hundreds nm.

  The porous layer used in the present invention is not particularly limited as long as it is a layer made of a porous substance and can carry a functional material. Preferred specific examples of the porous material include carbon-based material particles such as carbon particles, carbon nanotubes, carbon nanophones, and fullerenes. The porous layer may be a layer composed of one type of porous substance or a layer composed of two or more types of porous substances. The porous layer may be formed on another layer or may be formed of the porous layer itself.

  In the method for forming a functional porous layer of the present invention, a solution or a dispersion containing a functional material is applied to the porous layer, and a solution or a dispersion of the functional material (hereinafter, referred to as a “functional material liquid”) (Hereinafter referred to as "step (1)") and a step of removing the solvent or the solvent contained in the solution (hereinafter referred to as "step (II)").

  In the step (1), liquids of a plurality of types of functional materials having different surface tensions are preferably applied to the porous layer so that the amount of the functional material changes in a depth direction of the porous layer. The porous layer is impregnated with a functional material so that the amount of the functional material continuously decreases, more preferably, from the surface side toward the inside of the layer.

  Generally, when impregnating a substance in a porous layer, as the surface tension of the substance (solution or dispersion) to be impregnated is larger, the range of impregnation in the depth direction becomes narrower, and the surface tension is smaller. The greater the degree of impregnation in the depth direction. The present invention utilizes this phenomenon. That is, the present invention applies a liquid of a plurality of types of functional substances having different surface tensions to a porous layer and impregnates the same so that a functional substance having a desired concentration is provided at a desired position in the depth direction of the porous layer. This is to form a functional porous layer that is present.

  In the present invention, a liquid of a functional material having a relatively low surface tension is applied to a porous layer, and the porous layer is impregnated with the liquid. It is preferable to apply the liquid of the functional material to the porous layer so as to impregnate the porous layer. The reason is as follows.

  A liquid of a functional material having a surface tension of AlmN / m is applied on the porous layer and impregnated into the porous layer, and then a liquid of a functional material having a surface tension of A2 mN / m larger than A1 is applied to the porous layer. When the liquid is coated on the porous layer and impregnated into the porous layer, when the liquid of the functional material having the surface tension of A1 is used, the functional material is applied from the surface of the porous layer to the depth d1. Is uniformly diffused. When a liquid of a functional material having a surface tension of A2 is used, the liquid is uniformly diffused from the surface of the porous layer to a depth d2 (d1> d2). In other words, if the same functional material is used both when the surface tension is A1 and when the surface tension is A2, the same functional material is relatively present from the vicinity of the surface of the porous layer to the depth direction (d1). A state in which the functional material is distributed such that the amount is continuously reduced can be obtained.

  Further, when a solution or dispersion of a functional material is applied to the porous layer, the landed liquid does not spread in the lateral direction but permeates in the depth direction of the porous layer. Therefore, even if a material having a high surface tension is applied, the depth of penetration of the functional material in the depth direction can be controlled by applying the solvent later.

  This method can be specifically performed as follows.

  A predetermined amount of a solution or dispersion of the first functional material having the first concentration is applied to the porous layer. Next, a predetermined amount of the solvent is applied to the same position where the solution or dispersion of the first functional material is applied (first step). This makes it possible to control the penetration of the functional material into the porous layer in the depth direction.

  Next, a solution or dispersion of a second functional material having a second concentration is applied to the porous layer. Further, a predetermined amount of the solvent is applied to the same position as the position where the solution or dispersion liquid of the second functional material is applied (second step). By repeating this step, a concentration distribution can be provided in the depth direction of the porous layer of the functional material. In this case, it is also preferable to provide a step of removing the solvent (drying step) between the first step and the second step.

  In the present embodiment, two types of liquids of functional materials having different surface tensions have been described as examples. However, the surface tension of the functional material liquid is changed in multiple steps, and three or more types of liquids having different surface tensions are used. The liquid of the functional material may be used.

  The functional material used in the present invention is not particularly limited as long as it is a substance that exhibits functions such as chemical reactivity, electrical conductivity, and photoresponsiveness by being supported by a porous substance. Preferred specific examples include fine particles of one or more metals selected from the group consisting of platinum, rhodium, ruthenium, iridium, palladium, osmium, and alloys of two or more of these.

  The solvent for dissolving or dispersing the functional material is not particularly limited, and examples thereof include water, alcohols, ketones, esters, ethers, hydrocarbons, aromatic hydrocarbons, and combinations of two or more of these. Is mentioned.

  The method for preparing the liquids of the functional materials having different surface tensions is not particularly limited. For example, when using platinum fine particles as a functional material, an organic solvent such as alcohols, glycerin, and ethylene glycol is added to water at a predetermined ratio, or a surfactant and the like are added to water at a predetermined ratio. In addition, it is possible to prepare a dispersion liquid of platinum fine particles having a wide range of surface tension from the value of water to 20 mN / m. Further, a solution or dispersion having a predetermined surface tension can be prepared by changing the concentration of the solution or dispersion of the functional material.

  In the present invention, it is preferable that the application of the liquid of the functional material is performed using a discharge device. As the ejection device, the same device as the ejection device 20a described later can be used. When the functional material is applied using the discharge device, a required amount of the liquid of the functional material can be accurately applied to a desired application position. Therefore, not only can the liquid of the desired amount of the functional material be applied accurately, but also it is possible to apply the functional material accurately only to the position where the functional material is to be applied and impregnated. A functional porous layer having a material concentration distribution (depth direction and horizontal direction) can be easily formed.

  Further, a discharge device having a plurality of discharge nozzles may be used. In the case of using such a discharge device, for example, after the functional material liquid is applied at a predetermined application interval over the entire region where the functional material liquid is applied, the functional material is further applied during the application interval. When applying a liquid, the liquid of the functional material can be discharged from different discharge nozzles. According to this discharge device, it is possible to reduce an error in the amount of one application generated between the discharge nozzles as a whole.

  It is preferable to apply the liquid of the functional material at a sufficient interval (for example, about 1 mm) and to apply the liquid in small amounts (for example, 10 picoliters). After the solvent is distilled off, the deposition stage of the functional material changes, and therefore, to obtain a functional porous layer in which the functional material is uniformly dispersed, it is preferable that the application intervals are always the same.

  Next, in the step (II), it is possible to form a porous layer in which the functional material is carried (or adsorbed) in the porous layer by removing a solvent in which the functional material is dissolved or dispersed. it can.

  As a method of removing the solvent in which the functional material is dissolved or dispersed, a method of evaporating and removing by heating is generally used. In the present invention, since the heat treatment at a high temperature for a long time may destroy the dispersion state of the functional material formed in the step (I), it is preferable to remove the solvent as short as possible and at a low temperature. Specifically, a method of removing the solvent under reduced pressure at a low temperature, preferably at 100 ° C. or lower is preferable.

  According to the method for forming a functional porous layer of the present invention, a functional porous layer in which a functional material is distributed so as to change in the depth direction can be easily formed. The method for forming a functional porous layer of the present invention can be suitably applied to formation of a reaction layer of a fuel cell described below.

2) Fuel Cell Manufacturing Method The fuel cell manufacturing method of the present invention is directed to a fuel cell in which a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer are formed. The method according to claim 1, wherein at least one of the first reaction layer and the second reaction layer is formed of a plurality of types of solutions or dispersions of reaction layer forming materials having different surface tensions by using a porous material comprising carbon-based material particles. It is formed by applying to a porous layer and removing a solvent contained in the solution or dispersion.

  The method for manufacturing a fuel cell according to the present invention can be carried out using the fuel cell manufacturing apparatus (fuel cell manufacturing line) shown in FIG. In the fuel cell production line shown in FIG. 1, the discharge devices 20a to 20m used in each step, a belt conveyor BC1 connecting the discharge devices 20a to 20k, a belt conveyor BC2 connecting the discharge devices 201 and 20m, and a belt conveyor BC1 are used. , BC2, an assembly device 60 for assembling the fuel cell, and a control device 56 for controlling the entire fuel cell production line.

  The discharge devices 20a to 20k are arranged in a line at a predetermined interval along the belt conveyor BC1, and the discharge devices 201 and 20m are arranged in a line at a predetermined interval along the belt conveyor BC2. The control device 56 is connected to the ejection devices 20a to 20k, the driving device 58, and the assembling device 60.

  In this fuel cell production line, the belt conveyor BC1 driven by the driving device 58 is driven, and a substrate of the fuel cell (hereinafter, simply referred to as a "substrate") is transported to each of the discharge devices 20a to 20k and each of the discharge devices 20a to 20k. Processing in 20a to 20k is performed. Similarly, the belt conveyor BC2 is driven based on a control signal from the control device 56, the substrate is transported to the ejection devices 201 and 20m, and the processing in the ejection devices 201 and 20m is performed. In the assembling apparatus 60, the fuel cell assembling operation is performed using the substrates transported by the belt conveyors BC1 and BC2 based on a control signal from the control apparatus 56.

  The discharge devices 20a to 20m are not particularly limited as long as they are ink jet type discharge devices. For example, there are a thermal discharge device that discharges droplets by generating bubbles by heating and foaming, and a piezo discharge device that discharges droplets by compression using a piezo element.

  In the present embodiment, the discharge device shown in FIG. 2 is used as the discharge device 20a. The discharge device 20 a includes a tank 30 for storing the discharge 34, an inkjet head 22 connected to the tank 30 via a discharge transfer pipe 32, a table 28 for mounting and transporting the discharge target, and a stay in the inkjet head 22. And a waste liquid tank 48 for storing the excess discharged matter sucked by the suction cap 40. .

  The tank 30 accommodates a discharge 34 such as a resist solution, and has a liquid level control sensor 36 for controlling the height of the liquid level 34 a of the discharge contained in the tank 30. The sensor 36 controls the height difference h (hereinafter referred to as “water head value”) between the tip 26 a of the nozzle forming surface 26 of the inkjet head 22 and the liquid surface 34 a in the tank 30 within a predetermined range. I do. For example, by controlling the height of the liquid surface 34a so that the water head value is within 25 mm ± 0.5 mm, the discharged material 34 in the tank 30 can be sent to the inkjet head 22 at a pressure within a predetermined range. it can. By sending the discharge 34 at a pressure within a predetermined range, a required amount of the discharge 34 can be stably discharged from the inkjet head 22.

  The discharge transport pipe 32 includes a discharge flow path ground joint 32a for preventing electrification in the flow path of the discharge transport pipe 32, and a head section bubble exhaust valve 32b. The head-portion air bubble elimination valve 32b is used when the ejected matter in the inkjet head 22 is sucked by the suction cap 40 described later.

  The ink jet head 22 includes a head body 24 and a nozzle forming surface 26 on which a number of nozzles for discharging a discharge are formed, and a gas flow path for supplying a discharge, for example, a reaction gas from the nozzles of the nozzle formation surface 26. A resist solution or the like that is applied to the substrate when the substrate is formed on the substrate is discharged. The table 28 is installed movably in a predetermined direction. The table 28 moves in the direction indicated by the arrow in the figure, and places the substrate conveyed by the belt conveyor BC1, and takes it into the discharge device 20a.

  The suction cap 40 is movable in the direction of the arrow shown in FIG. 2, closely adheres to the nozzle forming surface 26 so as to surround the plurality of nozzles formed on the nozzle forming surface 26, and is located between the nozzle cap 26 and the nozzle forming surface 26. The structure is such that a closed space is formed so that the nozzle can be shielded from the outside air. That is, when the suction cap 40 sucks an object in the ink-jet head 22, the head-portion bubble elimination valve 32b is closed so that the discharged material does not flow from the tank 30 side. Accordingly, it is possible to increase the flow rate of the ejected matter to be sucked and quickly discharge the bubbles in the inkjet head 22.

  A flow path is provided below the suction cap 40, and a suction valve 42 is disposed in the flow path. The suction valve 42 has a role of closing the flow path for the purpose of shortening the time for maintaining the pressure balance (atmospheric pressure) between the suction side below the suction valve 42 and the ink jet head 22 above. A suction pump 46 including a suction pressure detection sensor 44 for detecting a suction abnormality and a tube pump is disposed in the flow path. The discharged material 34 sucked and conveyed by the suction pump 46 is temporarily stored in a waste liquid tank 48.

  In the present embodiment, the discharge devices 20b to 20m have the same configuration as the discharge device 20a except that the type of the discharge object 34 is different. Therefore, hereinafter, the same reference numerals are used for the same configuration of each ejection device.

  Next, each step of manufacturing a fuel cell using the fuel cell manufacturing line shown in FIG. 1 will be described. FIG. 3 shows a flowchart of a method for manufacturing a fuel cell using the fuel cell manufacturing line shown in FIG.

  As shown in FIG. 3, the fuel cell according to the present embodiment includes a step of forming a gas flow path in a first substrate (S10, a first gas flow path forming step), and a first support in a gas flow path. Step of applying a member (S11, first support member applying step), step of forming a first current collecting layer (S12, first current collecting layer forming step), step of forming a first gas diffusion layer (S13, first gas diffusion layer forming step), first reaction layer forming step (S14, first reaction layer forming step), step of forming an electrolyte membrane (S15, electrolyte membrane forming step), second step Forming a reaction layer (S16, second reaction layer forming step), forming a second gas diffusion layer (S17, second gas diffusion layer forming step), and forming a second current collecting layer Step (S18, second current collecting layer forming step), step of applying the second support member in the second gas flow path (S1) , The second support member application step), and a second second step (S20 of laminating substrates gas channel is formed, is manufactured by assembling step).

(1) First gas flow path forming step (S10)
First, as shown in FIG. 4A, a rectangular first substrate 2 is prepared, and the substrate 2 is transported to a discharge device 20a by a belt conveyor BC1. The substrate 2 is not particularly limited, and a substrate used for a normal fuel cell such as a silicon substrate can be used. In the present embodiment, a silicon substrate is used.

  The substrate 2 transported by the belt conveyor BC1 is placed on the table 28 of the discharge device 20a and is taken into the discharge device 20a. In the discharge device 20a, a resist solution contained in the tank 30 of the discharge device 20a is applied to a predetermined position on the substrate 2 mounted on the table 28 via the nozzle of the nozzle forming surface 26, and A resist pattern (shaded in the figure) is formed on the surface of the substrate. As shown in FIG. 4B, the resist pattern is formed on a portion of the surface of the substrate 2 other than the portion forming the first gas flow path for supplying the first reaction gas.

  The substrate 2 on which the resist pattern is formed at a predetermined position is transported to the ejection device 20b by the belt conveyor BC1, placed on the table 28 of the ejection device 20b, and taken into the ejection device 20b. In the ejection device 20b, an etching solution such as an aqueous solution of hydrofluoric acid contained in the tank 30 is applied to the surface of the substrate 2 through the nozzle on the nozzle forming surface 26. The surface of the substrate 2 other than the portion where the resist pattern is formed is etched by the etchant, and as shown in FIG. 5 (a), the cross section of the substrate 2 has a U-shape extending from one side surface to the other side surface. A first gas flow path is formed. In addition, as shown in FIG. 5B, the surface of the substrate 2 on which the gas flow path is formed is cleaned by a cleaning device (not shown), and the resist pattern is removed. Next, the substrate 2 on which the gas flow path has been formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20c by the belt conveyor BC1.

(2) First support member application step (S11)
Next, a first support member for supporting the first current collecting layer is applied on the substrate 2 on which the first gas flow path is formed. In the application of the first support member, the substrate 2 is placed on the table 28 and taken into the discharge device 20c, and then the first support member 4 housed in the tank 30 is formed by the discharge device 20c. This is performed by discharging into a first gas flow path formed in the substrate 2 through a nozzle on the surface 26.

  The first support member used is inert to the first reaction gas, prevents the first current collecting layer from falling into the first gas flow path, and There is no particular limitation as long as it does not prevent the first reaction gas from diffusing. For example, carbon particles, glass particles and the like can be mentioned. In the present embodiment, porous carbon having a particle diameter of about 1 to 5 microns is used. By using porous carbon having a predetermined particle size as a support member, the reaction gas supplied through the gas flow channel diffuses upward from the gap between the porous carbons, so that the flow of the reaction gas is hindered. Disappears.

  FIG. 6 shows an end view of the substrate 2 to which the first support member 4 has been applied. The substrate 2 to which the first support member 4 has been applied is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20d by the belt conveyor BC1.

(3) First current collecting layer forming step (S12)
Next, a first current collecting layer for collecting electrons generated by the reaction of the first reaction gas is formed on the substrate 2. First, the substrate 2 conveyed to the discharge device 20d by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20d. In the discharging device 20d, a predetermined amount of the current-collecting layer forming material contained in the tank 30 is discharged onto the substrate 2 through the nozzles on the nozzle forming surface 26, thereby forming a third pattern having a predetermined pattern. One current collecting layer is formed.

  The current-collecting layer forming material to be used is not particularly limited as long as the material contains a conductive substance. Examples of the conductive substance include copper, silver, gold, platinum, and aluminum. These can be used alone or in combination of two or more. The current-collecting layer-forming material can be prepared by dispersing at least one of these conductive substances in an appropriate solvent and adding a dispersant as required.

  In the present embodiment, the application of the current-collecting layer forming material is performed using the discharge device 20d, so that a predetermined amount can be accurately applied to a predetermined position by a simple operation. Therefore, the amount of the current-collecting layer-forming material used can be greatly reduced, a current-collecting layer having a desired pattern (shape) can be efficiently formed, and the application interval of the current-collecting layer-forming material is changed depending on the location. Thereby, the gas permeability of the reaction gas can be easily controlled, and the type of the current-collecting layer forming material to be used can be freely changed depending on the application position.

  FIG. 7 shows an end view of the substrate 2 on which the first current collecting layer 6 is formed. As shown in FIG. 7, the first current collecting layer 6 is supported by the first support member 4 in the first gas flow path formed on the substrate 2 and falls into the first gas flow path. Not to be. The substrate 2 on which the first current collecting layer 6 is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20e by the belt conveyor BC1.

(4) First gas diffusion layer forming step (S13)
Next, a first gas diffusion layer is formed on the current collecting layer of the substrate 2. First, the substrate 2 transported to the discharge device 20e by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20e. In the discharge device 20e, the gas diffusion layer forming material contained in the tank 30 of the discharge device 20e is transferred to a predetermined position on the surface of the substrate 2 placed on the table 28 via the nozzle of the nozzle forming surface 26. To form a first gas diffusion layer.

  As a gas diffusion layer forming material to be used, carbon particles are transportable, but carbon nanotubes, carbon nanophones, fullerenes and the like can also be used. In the present embodiment, since the gas diffusion layer is formed using the coating device 20e, for example, the coating interval is increased (several + μm) on the current collecting layer side, and reduced (several tens nm) on the surface side. In this way, the flow diffusion width of the reaction gas is reduced as much as possible by increasing the flow path width near the substrate, and the gas diffusion has a uniform and fine flow path near the reaction layer (surface side of the gas diffusion layer). Layers can be easily formed. Alternatively, carbon fine particles may be used on the substrate side of the gas diffusion layer, and a material having low gas diffusion ability but excellent catalyst carrying ability may be used on the surface side.

  FIG. 8 shows an end view of the substrate 2 on which the first gas diffusion layer 8 is formed. As shown in FIG. 8, the first gas diffusion layer 8 is formed on the entire surface of the substrate 2 so as to cover the first current collecting layer formed on the substrate. The gas diffusion layer 8 is a porous layer and plays a role of supporting a part of the gas diffusion layer 8 or a material for forming a reaction layer, as described in the next step. The substrate 2 on which the first gas diffusion layer 8 is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20f by the belt conveyor BC1.

(5) First reaction layer forming step (S14)
Next, a first reaction layer is formed on the substrate 2. The first reaction layer is formed so as to be electrically connected to the first current collecting layer via the gas diffusion layer 8. First, the substrate 2 conveyed to the discharge device 20f by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20f.

  Next, a predetermined amount of the solution or dispersion of the reaction layer forming material having a different surface tension, which is accommodated in the tank 30 of the discharge device 20f, is discharged to the first reaction layer forming site on the gas diffusion layer 8. The gas diffusion layer 8 is impregnated with the solution or dispersion of the reaction layer forming material discharged onto the gas diffusion layer 8. By repeating this operation, a coating film of the reaction layer forming material is formed on the gas diffusion layer 8 and, at the same time, the reaction layer forming material is formed in the surface portion of the gas diffusion layer 8 from the surface portion toward the substrate. A state in which the abundance changes continuously can be obtained.

  Examples of the solution or dispersion of the reaction layer forming material to be used include (a) a solution of a metal compound (metal complex, metal salt), and (b) a dispersion of metal-carrying carbon having a metal hydroxide adsorbed on a carbon carrier. And a dispersion of (c) metal fine particles.

  Examples of the metal of the metal compound, metal hydroxide and metal fine particles used in the solutions and dispersions (a) to (c) include platinum, rhodium, ruthenium, iridium, palladium, osmium and two or more of these. One or two or more metals selected from the group consisting of alloys are exemplified, and platinum is particularly preferred.

  In the case where a solution or a dispersion of the reaction layer forming material having a different surface tension is discharged using the discharging device, the solution or the dispersion of the reaction layer forming material having a different surface tension is discharged from the same discharging device 20f. Alternatively, the solution or the dispersion of the reaction layer forming material having a different surface tension may be discharged from a different discharge device. For example, after discharging the solution or dispersion of the reaction layer forming material having a relatively small surface tension by the discharging device 20f, the surface tension is relatively large by the discharging device 20f ′ (not shown). A solution or dispersion of the reaction layer forming material may be discharged.

  According to the present invention, the solution or the dispersion of the reaction layer forming material is applied and impregnated on the gas diffusion layer 8 while changing the surface tension in a stepwise (or continuous) manner. In 8, a reaction layer having a structure in which the amount of the material for forming a reaction layer continuously changes from the surface portion toward the substrate can be formed. Also, by appropriately setting the surface tension of the solution or dispersion of the reaction layer forming material to be used and the amount of application, the reaction layer in which the reaction layer forming material exists in an arbitrary distribution pattern in the depth direction can be easily formed. Can be formed.

  In the present invention, as a method of applying and impregnating a solution or dispersion of a reaction layer forming material having different surface tensions, it is preferable to use a method of sequentially applying and impregnating a solution having a lower surface tension. According to this method, it is possible to easily form a reaction layer in which the amount of the reaction layer forming material continuously decreases from the surface side of the gas diffusion layer 8 toward the first current collecting layer. it can.

  Further, in the present invention, applying the solution or the dispersion of the reaction layer forming material at predetermined intervals prevents aggregation of the fine particles of the reaction layer forming material, and the reaction layer forming material is uniformly dispersed. This is preferable because a reaction layer can be formed. The interval at which the solution or dispersion of the reaction layer forming material is applied is not particularly limited as long as the droplets of the solution or dispersion of the reaction layer forming material do not contact each other at the time of impact. From the viewpoint of efficiently forming a reaction layer having an amount of the reaction layer forming material, the size of the droplet is reduced (for example, 10 picoliters or less), and a sufficient application interval is provided (for example, 0.1 to 1 mm). Degree) is preferable.

  After repeating the application or the impregnation of the gas diffusion layer 8 with the solution or dispersion of the reaction layer forming material by the discharge device 20f, the solvent dissolving or dispersing the reaction layer forming material is removed. Thereby, a structure in which the material for forming a reaction layer is supported on carbon particles can be obtained.

  As a method for removing the solvent in which the reaction layer forming material is dissolved or dispersed, a method in which the solvent is removed by heating at normal pressure under an inert gas atmosphere, or a method in which the solvent is removed by heating under reduced pressure Although the method is mentioned, the latter method is preferable.

  The heating temperature is preferably as low as possible, more preferably 100 ° C or lower, and further preferably 50 ° C or lower. Further, it is preferable that the treatment for removing the solvent is performed in as short a time as possible. When the solvent is removed for a long time at a high temperature, the uniform dispersion state of the reaction layer forming material produced by the discharge device is broken, and the reaction layer in which the fine particle reaction layer forming material is uniformly dispersed is obtained. May not be possible.

  FIG. 9 is a conceptual diagram showing a state in which the first reaction layer 10 is formed on the first gas diffusion layer 8 as described above. As shown in FIG. 9, the first reaction having a structure in which the amount of the particulate reaction layer forming material 10 a is continuously reduced from the surface of the first gas diffusion layer 8 toward the substrate. A layer 10 has been formed. Further, in the conceptual diagram shown in FIG. 9, a part of the first gas diffusion layer 8 also serves as the first reaction layer 10.

  FIG. 10 is an end view of the substrate 2 on which the first reaction layer 10 is formed as described above. The substrate 2 on which the first reaction layer 10 is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharging device 20g by the belt conveyor BC1.

(6) Electrolyte membrane forming step (S15)
Next, an electrolyte membrane is formed on the substrate 2 on which the first reaction layer 10 has been formed. First, the substrate 2 transported to the discharge device 20g by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20g. In the discharge device 20g, the electrolyte film forming material contained in the tank 30 is discharged onto the first reaction layer 10 through the nozzle on the nozzle forming surface 26 to form the electrolyte film 12.

  Examples of the material for forming the electrolyte membrane to be used include a polymer electrolyte material obtained by micellizing perfluorosulfonic acid such as Nafion (manufactured by DuPont) in a mixed solution of water and methanol at a weight ratio of 1: 1. And a material in which a ceramic-based solid electrolyte such as tungstophosphoric acid or molybdophosphoric acid is adjusted to a predetermined viscosity (for example, 20 mPa · s or less).

  FIG. 11 shows an end view of the substrate 2 on which the electrolyte membrane is formed. As shown in FIG. 11, an electrolyte film 12 having a predetermined thickness is formed on the first reaction layer 10. The substrate 2 on which the electrolyte membrane 12 is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20h by the belt conveyor BC1.

(7) Second reaction layer forming step (S16)
Next, a second reaction layer is formed on the substrate 2 on which the electrolyte membrane 12 has been formed. The second reaction layer is formed by applying a material for forming a reaction layer on a substrate on which a gas flow path and a gas diffusion layer are formed while flowing an inert gas through the gas flow path.

  First, the substrate 2 transported to the discharge device 20h by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20h. In the ejection device 20h, the second reaction layer 10 'is formed by the same process as that performed in the ejection device 20f. As a material for forming the second reaction layer 10 ', the same material as that for the first reaction layer can be used.

  FIG. 12 shows an end view of the substrate 2 in which the second reaction layer 10 ′ is formed on the electrolyte membrane 12. As shown in FIG. 12, a second reaction layer 10 'is formed on the electrolyte membrane 12. In the second reaction layer 10 ', the reaction of the second reaction gas is performed. The substrate 2 on which the second reaction layer 10 'has been formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20i by the belt conveyor BC1.

(8) Second gas diffusion layer forming step (S17)
Next, a second gas diffusion layer is formed on the substrate 2 on which the second reaction layer 10 'has been formed. First, the substrate 2 transported to the discharge device 20i by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20i. In the ejection device 20i, the second gas diffusion layer 8 'is formed by the same process as that performed in the ejection device 20e. As the material for forming the second gas diffusion layer, the same material as the first gas diffusion layer 8 can be used.

  FIG. 13 shows an end view of the substrate 2 on which the second gas diffusion layer 8 'is formed. The substrate 2 on which the second gas diffusion layer 8 'is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed to the discharge device 20j by the belt conveyor BC1.

(9) Second current collecting layer forming step (S18)
Next, a second current collecting layer is formed on the substrate 2 on which the second gas diffusion layer 8 'has been formed. First, the substrate 2 transported to the discharge device 20j by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20j, and the second collection is performed by the same process as that performed in the discharge device 20d. An electrical layer 6 'is formed on the second gas diffusion layer 8'. As the material for forming the second current collecting layer, the same material as the material for forming the first current collecting layer can be used. The substrate 2 on which the second current collecting layer 6 'is formed is transferred from the table 28 to the belt conveyor BC1, and is conveyed by the belt conveyor BC1 to the discharge device 20k.

(10) Second support member application step (S19)
Next, the substrate 2 conveyed to the discharge device 20k by the belt conveyor BC1 is placed on the table 28 and taken into the discharge device 20k, and the second process is performed by the same process as that performed in the discharge device 20c. A support member is applied. As the second support member, the same one as the first support member can be used.

  FIG. 14 shows an end view of the substrate 2 on which the second current collecting layer 6 'and the second support member 4' are applied. The second support member 4 ′ is formed on the second current collecting layer 6 ′, and is located at a position accommodated in a second gas flow channel formed on the second substrate laminated on the substrate 2. It has been applied.

(11) Second board assembly process (S20)
Next, the substrate 2 on which the second support member 4 'is applied and the second substrate 2' on which a separately prepared second gas flow path is formed are stacked. The lamination of the first substrate and the second substrate is performed such that the second support member 4 ′ formed on the substrate 2 is accommodated in the second gas flow path formed on the second substrate. This is done by bonding to Here, the same substrate as the first substrate can be used as the second substrate. Further, the formation of the second gas flow path is performed in the ejection devices 201 and 20m by the same process as that performed by the ejection devices 20a and 20b.

  As described above, the fuel cell having the structure shown in FIG. 15 can be manufactured. The fuel cell shown in FIG. 15 has a first substrate 2, a first gas flow path 3 formed in the first substrate 2, and a first gas flow path 3 housed in the first gas flow path 3 from below in the drawing. First support member 4, first current collecting layer 6 formed on first substrate 2 and first support member 4, first gas diffusion layer 8, and first gas diffusion layer 8. A first reaction layer 10 formed on the layer 8, an electrolyte membrane 12, a second reaction layer 10 ', a second gas diffusion layer 8', a second current collecting layer 6 ', It comprises two gas flow paths 3 ′, a second support member 4 ′ housed in the second gas flow path 3 ′, and a second substrate 2 ′.

  The first reaction layer 10 and the second reaction layer 10 'of the fuel cell shown in FIG. 15 have a reaction layer forming material supported on carbon particles, and the amount of the reaction layer forming material depends on the reaction amount. The layer is formed to be higher on the electrolyte membrane side than on the current collector layer side. Therefore, a reaction layer having a uniform and desired amount of metal fine particles is efficiently formed, and the fuel cell has low cost, high output density, and excellent characteristics.

  In the fuel cell shown in FIG. 15, a U-shaped first gas flow path extending from one side surface formed on the substrate 2 to the other side surface and a second gas flow path formed on the substrate 2 ′ are formed. The substrate 2 'is arranged so that the gas flow path is parallel.

  The type of the fuel cell according to the present embodiment is not particularly limited. For example, a polymer electrolyte fuel cell, a phosphoric acid fuel cell, a direct methanol fuel cell and the like can be mentioned.

The fuel cell shown in FIG. 15 operates as follows. That is, the first reaction gas is introduced from the first gas flow path 3 of the first substrate 2, is uniformly diffused by the gas diffusion layer 8, and the diffused first reaction gas is supplied to the first reaction layer 10. To generate ions and electrons, and the generated electrons are collected by the current collecting layer 6 and flow to the second current collecting layer 6 ′ of the second substrate 2 ′, and the ions generated by the first reaction gas are The inside of the electrolyte membrane 12 moves to the second reaction layer 10 '. On the other hand, the second reaction gas is introduced from the gas passage 3 ′ of the second substrate 2 ′, is uniformly diffused by the second gas diffusion layer 8 ′, and the diffused second reaction gas is In the reaction layer 10 ′, the ions react with the ions moving in the electrolyte membrane 12 and the electrons sent from the second current collecting layer 6 ′. For example, when the first reaction gas is hydrogen gas and the second reaction gas is oxygen gas, in the first reaction layer 10, the reaction of H ₂ → 2H ⁺ + 2e ⁻ progresses, in 2 of the reaction layer ^{_{10 ', 1/20 2 +}} 2H + + 2e - → the reaction of _{H 2} 0 progresses.

  In the method for manufacturing a fuel cell according to the above-described embodiment, the discharge device is used in all the steps. However, the fuel cell can be manufactured using the discharge device in any of the steps for manufacturing the fuel cell. For example, a first reaction layer and / or a second reaction layer are formed by applying a reaction layer forming material using a discharge device, and in other steps, a fuel cell is manufactured by the same steps as those in the related art. You may do so. Even in this case, since the reaction layer can be formed without using MEMS (Micro Electro Mechanical System), the manufacturing cost of the fuel cell can be suppressed.

  In the manufacturing method of the above-described embodiment, a gas flow path is formed by forming a resist pattern on a substrate, applying a hydrofluoric acid aqueous solution and performing etching, but without forming a resist pattern. A gas flow path can also be formed. Alternatively, the gas flow path may be formed by placing the substrate in a fluorine gas atmosphere and discharging water to a predetermined position on the substrate. Further, the gas flow path may be formed by applying a gas flow path forming material on the substrate by using a discharge device.

  In the manufacturing method according to the above-described embodiment, the fuel cell is manufactured by forming constituent parts of the fuel cell from the first substrate side to which the first reaction gas is supplied, and finally stacking the second substrate. However, the production of the fuel cell may be started from the substrate to which the second reaction gas is supplied.

  In the manufacturing method of the above-described embodiment, the second support member is applied along the first gas flow path formed on the first substrate, but is applied so as to intersect with the first gas flow path. It may be applied in any direction. That is, the direction in which the second support member extends from the right side surface to the left side surface in FIG. 5B, for example, so as to intersect at right angles with the gas flow path formed in the first substrate, for example. May be applied. In this case, the second substrate is formed such that the second gas passage formed in the second substrate and the first gas passage formed in the first substrate intersect at right angles. Is obtained.

  In the manufacturing method according to the above-described embodiment, the first current collecting layer, the first reaction layer, the electrolyte membrane, the second reaction layer, and the second reaction layer are formed on the first substrate on which the first gas flow path is formed. 2 are sequentially formed, but a current collecting layer, a reaction layer, and an electrolyte film are formed on each of the first substrate and the second substrate, and finally, the first substrate, the second substrate, By joining them, a fuel cell can also be manufactured.

  In the fuel cell manufacturing line of the present embodiment, a first manufacturing line for processing a first substrate and a second manufacturing line for processing a second substrate are provided, and the processing in each manufacturing line is performed in parallel. A production line is used. Therefore, since the processing on the first substrate and the processing on the second substrate can be performed in parallel, the fuel cell can be manufactured quickly.

3) Electronic device and automobile An electronic device according to the present invention includes the above-described fuel cell as a power supply source. Examples of the electronic device include a mobile phone, a PHS, a mobile, a notebook computer, a PDA (Personal Digital Assistant), a mobile video phone, and the like. Further, the electronic device of the present invention may have other functions such as a game function, a data communication function, a recording / reproducing function, and a dictionary function. ADVANTAGE OF THE INVENTION According to the electronic device of this invention, the clean energy which considered the global environment appropriately can be provided as a power supply source.

  A vehicle according to the present invention includes the above-described fuel cell as a power supply source. According to the manufacturing method of the present invention, a large fuel cell can be manufactured by stacking a plurality of fuel cells. That is, as shown in FIG. 16, a gas flow path is further formed on the back surface of the substrate 2 'of the manufactured fuel cell, and the above-described fuel cell manufacturing method is formed on the back surface of the substrate 2' on which the gas flow path is formed. A large-sized fuel cell can be manufactured by forming a gas diffusion layer, a reaction layer, an electrolyte membrane and the like and stacking the fuel cells in the same manner as in the manufacturing process of the above. ADVANTAGE OF THE INVENTION According to the vehicle of this invention, the clean energy which considered the global environment appropriately can be provided as a power supply source.

FIG. 2 is a diagram showing an example of a fuel cell production line according to the embodiment. It is a schematic diagram of an ink jet type ejection device concerning an embodiment. 4 is a flowchart of a method for manufacturing a fuel cell according to an embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is a diagram illustrating a process of forming a gas flow channel according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 3 is a conceptual diagram of a reaction layer according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 4 is an end view of the substrate in a process of manufacturing the fuel cell according to the embodiment. FIG. 2 is an end view of the fuel cell according to the embodiment. It is a figure of a large-sized fuel cell which laminated a fuel cell concerning an embodiment.

Explanation of reference numerals

2 1st board | substrate, 2 '... 2nd board | substrate, 3 ... 1st gas flow path, 3' ... 2nd gas flow path, 4 ... 1st support member, 4 '... 2nd support member , 6: first current collecting layer, 6 ': second current collecting layer, 8: first gas diffusion layer, 8': second gas diffusion layer, 10a: material for forming a reaction layer, 10 ... 1 reaction layer, 10 ': second reaction layer, 12: electrolyte membrane, 20a to 20m: discharge device, BC1, BC2: belt conveyor.

Claims (22)

  A method for forming a functional porous layer in which a functional material is supported on a porous substance, comprising applying a plurality of types of functional material solutions or dispersions having different surface tensions to the porous layer, A method for forming a functional porous layer, comprising controlling the penetration of the functional material in the depth direction of the porous layer by a difference in tension.   The functional porous layer may be formed by applying a solution or dispersion of a functional material having a plurality of different surface tensions to the porous layer and removing a solvent contained in the solution or dispersion. The method for forming a functional porous layer according to claim 1, wherein:   The method for forming a functional porous layer according to claim 1, wherein the functional porous layer is formed such that an amount of the functional material changes in a depth direction of the porous layer.   A step of applying a solution or dispersion of the functional material to the porous layer and impregnating the porous layer with the solution or dispersion of the functional material uses a solution or dispersion of the functional material having a different surface tension. The method for forming a functional porous layer according to any one of claims 1 to 3, wherein the method is repeated a plurality of times.   The method of forming a functional porous layer according to claim 4, wherein the concentration of the solution or dispersion of the functional material is changed each time.   After applying the solution or dispersion of the first functional material to the porous layer and impregnating the porous layer with the solution or dispersion of the first functional material, the solution of the first functional material is dispersed. Or having a surface tension greater than the dispersion, applying a solution or dispersion of a second functional material to the porous layer and impregnating the solution or dispersion of the second functional material, A method for forming a functional porous layer according to claim 1.   The solution or the dispersion of the functional materials having different surface tensions is prepared by dissolving or dispersing the functional materials in different kinds of solvents, and is prepared according to any one of claims 1 to 6. Method for forming a functional porous layer.   The method for forming a functional porous layer according to any one of claims 1 to 7, wherein the porous layer is a porous layer made of carbon-based material particles.   The functional porous layer is formed of one or more metal particles selected from the group consisting of platinum, rhodium, ruthenium, iridium, palladium, osmium, and an alloy composed of two or more of these. The method for forming a functional porous layer according to any one of claims 1 to 8, characterized in that the functional porous layer is carried on a substrate.   As the solution or dispersion of the functional material, fine particles of one or more metals selected from the group consisting of platinum, rhodium, ruthenium, iridium, palladium, osmium and alloys of two or more thereof, or the metal The method for forming a functional porous layer according to any one of claims 1 to 9, wherein a solution or dispersion of the compound is used.   The fuel cell in which the functional porous layer is formed of a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer in this order. The method for forming a functional porous layer according to any one of claims 1 to 10, wherein the method is at least one of a first reaction layer and a second reaction layer.   The method for forming a functional porous layer according to any one of claims 1 to 11, wherein the application of the solution or dispersion of the functional material is performed using a discharge device.   A method for manufacturing a fuel cell, comprising forming a first current collecting layer, a first reaction layer, an electrolyte membrane, a second reaction layer, and a second current collecting layer, wherein the first reaction layer and the second At least one of the reaction layers is coated with a solution or dispersion of a plurality of reaction layer forming materials having different surface tensions on a porous layer made of carbon-based material particles to remove a solvent contained in the solution or dispersion. A method for manufacturing a fuel cell, comprising:   At least one of the first reaction layer and the second reaction layer is formed so that the amount of the reaction layer forming material changes in the depth direction of the porous layer made of carbon-based material particles. 14. The method for manufacturing a fuel cell according to claim 13, wherein the material forms a reaction layer supported by carbon-based material particles.   At least one of the first reaction layer and the second reaction layer is coated with a solution or dispersion of a material for forming a reaction layer on a porous layer made of carbon-based material particles. 15. The method according to claim 13, wherein the step of impregnating the solution or the dispersion of the material is repeated by using a solution or a dispersion of the material for forming a reaction layer having a different surface tension. Of manufacturing a fuel cell.   At least one of the first reaction layer and the second reaction layer is coated with a solution or dispersion of a first reaction layer forming material on a porous layer made of carbon-based material particles, and the first reaction layer is formed. After impregnating with the solution or dispersion of the forming material, the solution or dispersion of the second reaction layer forming material having a higher surface tension than the solution or dispersion of the first reaction layer forming material, The method according to any one of claims 13 to 15, wherein the composition is formed by applying to a porous layer made of carbon-based material particles and impregnating with a solution or dispersion of the second reaction layer forming material. A method for manufacturing a fuel cell.   The solution or the dispersion of the reaction layer forming material having a different surface tension as a solution or a dispersion of the reaction layer forming material is prepared by dissolving or dispersing the reaction layer forming material in a different type of solvent, A method for manufacturing the fuel cell according to any one of the above.   At least one of the first reaction layer and the second reaction layer is coated with carbon-based material particles on the first current collecting layer or the second current collecting layer to form a porous layer made of carbon-based material particles. Form a layer, then apply a solution or dispersion of a plurality of reaction layer forming materials having different surface tensions to a porous layer composed of the carbon-based material particles, and remove a solvent contained in the solution or dispersion. The method for manufacturing a fuel cell according to claim 13, wherein the fuel cell is formed by removing.   The method according to any one of claims 13 to 18, wherein the application of the solution or the dispersion of the reaction layer forming material is performed using a discharge device.   At least one of the first reaction layer and the second reaction layer has metal fine particles supported on carbon-based material particles, and the amount of the metal fine particles is larger than the current collecting layer side of the reaction layer in the electrolyte membrane. 20. The method for manufacturing a fuel cell according to claim 13, wherein the side is formed to be higher.   An electronic device comprising a fuel cell manufactured by the manufacturing method according to claim 13 as a power supply source. An automobile comprising a fuel cell manufactured by the manufacturing method according to any one of claims 13 to 20 as a power supply source.

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