JP2006222020A - 燃料電池用触媒層の製造方法及び製造装置 - Google Patents
燃料電池用触媒層の製造方法及び製造装置 Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 25
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 61
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Abstract
【解決手段】 触媒層用担体としてカーボンナノウォール(CNW)等のナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程と、触媒成分及び/又は電解質成分を該触媒層用担体上に担持・分散させる工程とを含む燃料電池用触媒層の製造方法。
【選択図】 図3
Description
(1)触媒層の均一な薄膜化が困難
(2)生産性が低い(触媒層合成の工程数が多い)。
(3)工程数が多いことからコストが高い
(4)三相界面の形成が不十分となり、燃料ガスがうまく界面に到達せず、電池性能が十分に発揮できない(Ptの利用効率が低い)
(1)電解質に触媒を塗布するため、触媒をインク状にする必要がある。このインクを塗布する際、膜厚を均一にするのが困難であり、発電むらが生じる。材料同士の相性があるためインク自体の調製が難しい。
(2)従来の触媒層製造プロセスは、製造した担体に触媒成分を担持し、その後、電解質溶液を混合するという多段の工程を経る必要があり、生産性が低い。
(3)工程が多いため設備数や設備規模が増大しコストが増加する。
(4)従来の触媒層の製造プロセスは触媒金属を担持し、その後、電解質を含浸するため、触媒成分を電解質が覆ってしまい、電池性能を左右する三相界面の形成が不十分となる。そのため電池性能の低下を起こす可能性がある。
(b)同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程を行い、次いで、(2)触媒成分を該触媒層用担体上に担持・分散させる工程を行い、次いで(3)電解質成分を該触媒層用担体上に担持・分散させる工程とを行う。
(c)同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程を行い、次いで、(3)電解質成分を該触媒層用担体上に担持・分散させる工程を行い、次いで(2)触媒成分を該触媒層用担体上に担持・分散させる工程とを行う。
(d)同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程、(2)触媒成分を該触媒層用担体上に担持・分散させる工程、及び(3)電解質成分を該触媒層用担体上に担持・分散させる工程の全てを同時に行う。
図4に示す触媒層一段製造装置を用いた触媒層薄膜の製造プロセスを説明する。本実施例では、CNWを拡散層担体として用いる。同一チャンバー内で、担体(CNW)を製造すると同時に、レーザー、またはプラズマを用い、触媒成分と電解質(プロトン伝導性材料)を担体上に担持・分散し触媒層を製造する。触媒成分と電解質(プロトン伝導性材料)の担持・分散には、例えばレーザーアブレーション、プラズマ、アーク放電を用いる。ここで、触媒成分と電解質は順番に分散させるもしくは同時に分散させることができる。
図5に示す他の触媒層一段製造装置を用いた触媒層薄膜の製造プロセスを説明する。本実施例では、プラズマを発生させる高周波の他に、同じ電極に周波数の低い高周波を印加する。この時、当該電極表面に触媒となる金属、白金等を置いておけば、プラズマのスパッタにて金属ナノ粒子がプラズマ中に飛び出し、それらがCNW表面に担持される。又、プラズマ内に触媒金属を含むガス又は溶液を供給し、触媒金属をCNWに担持することもできる。ここで、供給方法はノズル等を広く用いることができる。
(1)CNWを用いることによって、後工程で成膜する必要がない。一段で製造できるので、低コスト、小設備が達成できる、
(2)触媒成分、電解質を高分散できる。電解質の混合量も簡単に制御でき、電解質が白金系触媒を覆ってしまい白金系触媒の活性を低下させるというようなことがない。白金系触媒の使用量が低減され、コストも低減できる、
という効果が奏される。
図4に示す触媒層一段製造装置を用いCNWを製造した後、Ptを担持したものの触媒性能のデータを示す。図4の装置を用い、アーク放電によってCNWにPtを担持した。アーク電圧は60V(最高:100V)、パルス幅1secとし、放電回数を100回とした。
Claims (10)
- 触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程と、触媒成分及び/又は電解質成分を該触媒層用担体上に担持・分散させる工程とを含む燃料電池用触媒層の製造方法。
- 前記ナノサイズ構造を有する炭素系多孔性材料がカーボンナノウォール(CNW)であることを特徴とする請求項1に記載の燃料電池用触媒層の製造方法。
- 同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程を行い、次いで、(2)触媒成分を該触媒層用担体上に担持・分散させる工程及び(3)電解質成分を該触媒層用担体上に担持・分散させる工程とを同時に行うことを特徴とする請求項1または2に記載の燃料電池用触媒層の製造方法。
- 同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程を行い、次いで、(2)触媒成分を該触媒層用担体上に担持・分散させる工程を行い、次いで(3)電解質成分を該触媒層用担体上に担持・分散させる工程とを行うことを特徴とする請求項1または2に記載の燃料電池用触媒層の製造方法。
- 同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程を行い、次いで、(3)電解質成分を該触媒層用担体上に担持・分散させる工程を行い、次いで(2)触媒成分を該触媒層用担体上に担持・分散させる工程とを行うことを特徴とする請求項1または2に記載の燃料電池用触媒層の製造方法。
- 同一チャンバー内で、(1)触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させる工程、(2)触媒成分を該触媒層用担体上に担持・分散させる工程、及び(3)電解質成分を該触媒層用担体上に担持・分散させる工程の全てを同時に行うことを特徴とする請求項1または2に記載の燃料電池用触媒層の製造方法。
- 前記(2)触媒成分を該触媒層用担体上に担持・分散させる工程及び/又は前記(3)電解質成分を該触媒層用担体上に担持・分散させる工程を、レーザーアブレーション、プラズマ放電、アーク放電、触媒及び/又は電解質を含むガス又は溶液を担体上に担持・分散させる方法から選択される1種以上により行うことを特徴とする請求項1乃至6のいずれかに記載の燃料電池用触媒層の製造方法。
- 請求項1乃至7のいずれかに記載の方法によって製造された燃料電池用触媒層を含む燃料電池。
- 同一チャンバー内に、触媒層用担体としてナノサイズ構造を有する炭素系多孔性材料を気相成長させるためのプラズマ発生装置、及び触媒成分及び/又は電解質成分を該触媒層用担体上に担持・分散させるためのレーザーアブレーション、プラズマ放電、アーク放電からから選択される1種以上の発生装置を備えたことを特徴とする燃料電池用触媒層の製造装置。
- 前記ナノサイズ構造を有する炭素系多孔性材料がカーボンナノウォール(CNW)であることを特徴とする請求項9に記載の燃料電池用触媒層の製造装置。
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US11/884,233 US20080274392A1 (en) | 2005-02-14 | 2006-02-14 | Method and Apparatus for Producing Catalyst Layer for Fuel Cell |
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DE112014000964T5 (de) | 2013-02-22 | 2015-11-05 | Sumitomo Electric Industries, Ltd. | Poröses Teil und Katalysatorteil |
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