JP2011076739A - Gas diffusion layer for solid polymer fuel cell, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a gas diffusion layer for a solid polymer fuel cell and a manufacturing method thereof with water-repellency improved without increasing internal electrical resistance. <P>SOLUTION: In the gas diffusion layer 10b, an intermediate layer 3 containing carbon powder and fluorine resin, a resin layer 2 containing fluorine resin, and a base material layer 1 containing carbon fiber are laminated in this order. Then, a ratio of carbon powder to fluorine resin of the resin layer 2 is lower than the ratio of carbon powder to fluorine resin of the intermediate layer 3, and the carbon fiber contained in the base material layer 1 penetrates the resin layer to contact with the intermediate layer. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a gas diffusion layer used for an electrode of a polymer electrolyte fuel cell and a method for producing the same.

  A polymer electrolyte fuel cell (hereinafter referred to as “PEFC”) uses a solid polymer membrane as an electrolyte and a fuel such as hydrogen as an anode electrode (positive electrode, hereinafter referred to as “anode”). It is a device that generates electricity by supplying an oxidant gas such as air (exactly oxygen in the air) to the cathode electrode (negative electrode, hereinafter referred to as “cathode”) to cause an electrochemical reaction. . A unit cell (hereinafter referred to as “single cell”), which is the smallest unit of a battery in PEFC, is a membrane in which electrodes (anode and cathode) are bonded to both sides of a solid polymer membrane, that is, an electrode assembly (Membrane Electrode Assembly). , Hereinafter referred to as “MEA”) is sandwiched between separators in which gas flow paths are formed. These single cells are stacked to form a PEFC cell stack.

  The anode and cathode of the PEFC include a gas diffusion layer and a catalyst layer. The gas diffusion layer is in direct contact with the catalyst layer and the separator, and has a function of conducting electricity and a function of efficiently guiding air and hydrogen necessary for a chemical reaction. Further, in the gas diffusion layer, a base material layer such as carbon paper is provided with an intermediate layer made of a carbonaceous material and a water-repellent resin in order to make the current density uniform and improve the water repellency.

  As such a gas diffusion layer and a manufacturing method thereof, for example, Patent Document 1 discloses a method of firing after forming an intermediate layer on a base material layer.

  In this gas diffusion layer, since the water repellency is insufficient, the durability performance of the PEFC is reduced due to flooding. The flooding is a phenomenon in which moisture is generated in the gas diffusion layer, and this moisture prevents a gas such as air or hydrogen from reaching the entire gas diffusion layer.

  As a method for suppressing this flooding, for example, in Patent Document 2, a first layer mainly composed of a resin having water repellency on a base material and a resin having a water repellency lower than that of the first layer as a main component. A gas diffusion layer provided with a second layer is disclosed.

JP 09-245801 A Japanese Patent Laid-Open No. 2005-071755

  However, in the gas diffusion layer shown in Patent Document 2, the durability of the PEFC due to flooding is likely to decrease because the water repellency of the first layer is insufficient, and the bonding between the first layer and the substrate is difficult. Since the adherence is insufficient, the first layer and the second layer are likely to be peeled off. As a result, there is a problem that the current density becomes non-uniform and the cell voltage tends to decrease. When the ratio of the resin (water repellent resin layer) of the first layer is increased in order to improve water repellency and binding properties, there is a problem that the cell voltage is lowered due to an increase in internal resistance.

  The present invention is mainly intended to solve the above-mentioned problem of durability performance of PEFC without lowering the cell voltage, and the solid polymer type with improved water repellency without increasing the internal resistance. It is an object of the present invention to provide a gas diffusion layer used for an electrode of a fuel cell and a manufacturing method thereof.

  The gas diffusion layer used for the electrode of the polymer electrolyte fuel cell according to the first invention includes a base material layer containing carbon fiber, a resin layer containing fluororesin, and an intermediate layer containing carbon powder and fluororesin. Arranged in order. And the ratio of the carbon powder with respect to the fluororesin of a resin layer is lower than the ratio of the carbon powder with respect to the fluororesin of an intermediate | middle layer, and the carbon fiber contained in a base material layer penetrates a resin layer, and contacts the said intermediate | middle layer It is characterized by that.

  In the gas diffusion layer according to the first invention, the water repellency can be improved by providing a resin layer containing more fluorine resin than the intermediate layer. And since the carbon powder of each conductive layer and the carbon fiber contained in the base material layer that penetrates the resin layer and contacts the intermediate layer form a current path, the electrical resistance is not provided with the resin layer. It does not increase even when compared with other gas diffusion layers.

  A gas diffusion layer according to a second invention is characterized in that, in the gas diffusion layer according to the first invention, the ratio of the mass of the carbon powder to the fluororesin of the intermediate layer is 20 mass% or more and 900 mass% or less. .

  Increasing the proportion of the carbon powder relative to the fluororesin of the resin layer or intermediate layer improves the conductivity, and conversely, decreasing the proportion of the carbon powder improves the water repellency. Here, in the ratio of the mass of the carbon powder to the fluororesin, 20% by mass is a mass ratio of the fluororesin and the carbon powder of 1: 0.2, and 900% by mass is the fluororesin and the carbon powder. The mass ratio of 1: 9 means 25% by mass means that the mass ratio of the fluororesin and the carbon powder is 1: 0.25. In addition, since it was difficult to prescribe | regulate the surface area of carbon and resin, it prescribed | regulated by the ratio of the mass of carbon and resin.

  In the gas diffusion layer according to the second invention, by defining the ratio of the carbon powder to the fluororesin of the resin layer or the intermediate layer as described above, the water repellency is enhanced in the resin layer, and the intermediate layer is more repellent than the resin layer. Although the water resistance is inferior, the electric resistance is reduced, and as a result, a gas diffusion layer having high water repellency can be obtained without increasing the electric resistance.

  The gas diffusion layer according to the third invention is the gas diffusion layer according to the first invention or the second invention, wherein the fluororesin of the resin layer and the intermediate layer is a tetrafluoroethylene-hexafluoropropylene copolymer ( Hereinafter, it is referred to as “FEP”).

  In the gas diffusion layer according to the third invention, in the gas diffusion layer according to the first invention or the second invention, the fluororesin of the resin layer and the intermediate layer is made water repellent and binding property in the conventional fluororesin. With excellent FEP, the binding property between the base material layer and the resin layer and the binding property between the resin layer and the intermediate layer are improved, and durability such as peeling is maintained while maintaining the water repellency of the gas diffusion layer. Can be improved.

  A method for producing a gas diffusion layer used for an electrode of a polymer electrolyte fuel cell according to a fourth aspect of the invention first includes an intermediate layer paste containing at least carbon powder and a fluororesin on a base material layer made of carbon fiber. It is dried (S2, S3). Then, the intermediate layer is fired (S4). Through steps S1 to S4, a laminate that is a laminate of the base material layer and the intermediate layer is obtained. And the solution containing a fluororesin is made to adhere to the laminated body which consists of a base material layer and the baked intermediate | middle layer (S5). And the excess solution adhering to the surface of the laminated body is removed (S6). And the laminated body which passed through the process (S6) is dried (S7), and the laminated body is baked after that (S9).

  In the method for producing a gas diffusion layer according to the fourth invention, the laminate of the base material layer and the fluororesin film undergoes the above-described steps (S4 to S7 and S9). A gas diffusion layer in which a resin layer containing a fluororesin is provided at the boundary portion can be obtained. In the gas diffusion layer, the carbon fiber penetrates the resin layer and comes into contact with the fluororesin film.

  A method for producing a gas diffusion layer according to a fifth invention is the method for producing a gas diffusion layer according to the fourth invention, wherein the step of attaching a solution containing a fluororesin to the laminate (S5) and the surface of the laminate It is characterized in that the step (S6) of removing the excess solution adhered and the step (S7) of drying the laminate after the step (S6) are repeated a predetermined number of times.

  In the method for manufacturing a gas diffusion layer according to the fifth invention, the thickness of the resin layer is increased by increasing the number of repetitions of the above steps (S5, S6, S7), and the amount of fluororesin in the resin layer is increased. it can.

  A method for producing a gas diffusion layer according to a sixth invention is the method for producing a gas diffusion layer according to the fourth invention or the fifth invention, wherein the fluororesin is a tetrafluoroethylene-hexafluoropropylene copolymer (FEP). ).

  In the method for producing a gas diffusion layer according to the sixth invention, a gas diffusion layer having the same configuration as that of the gas diffusion layer according to the third invention can be obtained.

  In the fourth to sixth inventions, as in the second invention, the ratio of the mass of the carbon powder to the fluororesin of the water repellent material is 20% by mass to 900% by mass, and the carbon powder to the fluororesin of the resin layer You may manufacture a gas diffusion layer so that the mass ratio may be 25 mass% or less. In this way, in particular, a gas diffusion layer having high water repellency can be obtained without increasing the electrical resistance.

  In the gas diffusion layer used for the electrode of the polymer electrolyte fuel cell and the manufacturing method thereof according to the present invention, durability such as water repellency and peeling is improved as compared with the conventional one without increasing the internal resistance of the single cell. A gas diffusion layer can be obtained. Thereby, durability of PEFC can be improved.

The figure which shows schematically the structure of the single cell using the gas diffusion layer which concerns on this invention. The figure which shows the outline of the cross section of the gas diffusion layer for polymer electrolyte fuel cells. (A) The figure which shows the outline of the cross section of the gas diffusion layer before formation of a resin layer. (B) The figure which shows the outline of the cross section of the gas diffusion layer of this embodiment after formation of a resin layer. (C) The figure which shows the outline of the cross section of the gas diffusion layer provided with the resin layer and making the carbon fiber of a base material layer not contact an intermediate | middle layer. The figure which shows the process of manufacture of the gas diffusion layer for polymer electrolyte fuel cells. The figure which shows the table | surface of the kind of gas diffusion layer. The figure which shows the relationship between the ratio [%] of the carbon powder with respect to the fluororesin of an intermediate | middle layer, and the decreasing rate [microvolt * h < ^-1 >] of single cell voltage. The figure which shows the relationship between the ratio [%] of the carbon powder with respect to the fluororesin of an intermediate | middle layer, and the single cell voltage [V]. The figure which shows the relationship between the ratio [%] of the carbon powder with respect to the fluororesin of an intermediate | middle layer, and the internal resistance [mohm * cm < ² >] of a single cell. The figure which shows the table | surface of the kind of the conventional gas diffusion layer provided with the resin layer and not making the carbon fiber of a base material layer contact an intermediate | middle layer. The figure which shows the relationship between the ratio [%] of the carbon powder with respect to the fluororesin of a resin layer, and single cell voltage [V]. The figure which shows the relationship between the ratio [%] of the carbon powder with respect to the fluororesin of a resin layer, and the internal resistance [mohm * cm < ² >] of a single cell.

(First embodiment)
FIG. 1 is a cross-sectional view schematically showing a laminated structure of a single cell using a gas diffusion layer 10b according to the present invention. The single cell 20 includes an electrode assembly (MEA) 16, an anode gasket 12a, a cathode gasket 12b, an anode side separator 14a, and a cathode side separator 14b. The MEA 16 includes an anode 13a and a cathode 13b on both surfaces of an electrolyte membrane 11 made of a solid polymer. The anode 13a and the cathode 13b are formed by laminating the gas diffusion layer 10b and the catalyst layer 5 according to the present invention. The anode gasket 12a and the cathode gasket 12b are provided around the anode 13a and the cathode 13b in order to prevent leakage of oxidant and fuel. The anode-side separator 14 a includes a flow path 15 (broken line) for circulating a methanol aqueous solution supplied to the anode 13 a on the surface facing the MEA 16. The cathode-side separator 14 b includes a flow path 15 for circulating air supplied to the cathode 13 b on the surface facing the MEA 16.

-Gas diffusion layer for polymer electrolyte fuel cells-
FIG. 2 is a diagram schematically showing a cross section of a gas diffusion layer for a polymer electrolyte fuel cell as an example. 2A is a diagram showing an outline of a cross section of the gas diffusion layer 10a before the formation of the resin layer 2, and FIG. 2B is a cross section of the gas diffusion layer 10b after the formation of the resin layer 2. FIG. The gas diffusion layer 10b is obtained by providing the resin layer 2 on the gas diffusion layer 10a. The carbon fibers 4 of the base material layer 1 of the gas diffusion layer 10 b are in contact with the intermediate layer 3.

  FIG. 2A shows a gas diffusion layer 10a in which an intermediate layer 3 containing carbon powder and a fluororesin, and a base material layer 1 made of carbon paper containing carbon fibers or the like are laminated in this order. Since the base material layer 1 and the intermediate layer 3 are the same as the gas diffusion layer 10b, they will be described in detail together with the following gas diffusion layer 10b.

  In FIG. 2B, an intermediate layer 3 containing carbon powder and a fluororesin, a resin layer 2 containing a fluororesin, and a base material layer 1 made of carbon paper containing carbon fibers 4 are laminated in this order. A gas diffusion layer 10b is shown. The base material layer 1 is a layer mainly having electrical conductivity and gas diffusibility. The resin layer 2 is a layer mainly having water repellency. The intermediate layer 3 is in the middle of the base material layer 1 and the catalyst layer 5 and is a layer mainly having conductivity, water repellency and binding properties.

  The electrode 13 of the anode 13 a and the cathode 13 b is formed by laminating the gas diffusion layer 10 b and the catalyst layer 5 so that the intermediate layer 3 is in contact with the catalyst layer 5.

  The base material layer 1 is mainly composed of carbon fibers 4. As the carbon fiber 4, a carbon material having a length of 10 times or more the fiber diameter, for example, carbon paper, carbon felt, carbon cloth, or the like can be used. The carbon fiber 4 may be sintered in order to increase electronic conductivity.

  The carbon fiber 4 penetrates the resin layer 2 and is in contact with the intermediate layer 3. Here, that the carbon fiber 4 is in contact with the intermediate layer 3 means a state in which the carbon fiber 4 and the intermediate layer 3 are electrically connected, and a state in which the tip of the carbon fiber 4 enters the inside of the intermediate layer 3. Say. Thereby, electrical connection is ensured, and even if the gas diffusion layer 10 has the resin layer 2 between the base material layer 1 and the intermediate layer 3, an increase in resistance can be suppressed.

  The base material layer 1 may contain a resin, thereby suppressing flooding. As the resin, a resin having strong water repellency such as polytetrafluoroethylene (PTFE) or tetrafluoroethylene-hexafluoropropylene copolymer (FEP) is preferably used, but a fluororesin having no ion exchange group. If it is. Examples of the material include polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), tetrafluoroethylene-perfluoroalkyl vinyl ether (PFA), polychlorotrifluoroethylene (PCTFE), and ethylene-chloroalkylethylene copolymer. (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFF), etc. can be used. Among these fluororesins, a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) having high water repellency and thermoplasticity is particularly preferable because of high water repellency and binding properties.

  The more holes in the base material layer 1, the better the gas diffusibility of the gas diffusion layer. However, when the number of holes in the base material layer 1 increases, the electron conduction path decreases, and the output characteristics of the fuel cell deteriorate. Therefore, in order to achieve both gas diffusibility and electronic conductivity, it is preferable to use the base material layer 1 having a porosity of 50% or more and 95% or less.

  The resin layer 2 is made of a fluororesin. The fluororesin serves as a water repellent for the intermediate layer 3 and as a binder for binding the intermediate layer and the base material layer. The resin layer 2 may contain carbon powder, but the ratio of the carbon powder to the fluororesin is preferably 25% by mass or less. The resin layer 2 may not contain carbon powder. Furthermore, the ratio of the carbon powder to the fluororesin of the resin layer 2 may vary depending on the width, depth and thickness of the resin layer 2 and a certain reference direction, or may be biased to a certain part.

  As the fluororesin of the resin layer 2, it is preferable to use a fluororesin having no ion exchange group in order to prevent flooding due to generated water accompanying the operation of PEFC. As this fluororesin, the same fluororesin as the base material layer 1 can be used. Moreover, like the base material layer 1, this fluororesin is particularly preferably a tetrafluoroethylene-hexafluoropropylene copolymer (FEP).

  The intermediate layer 3 is mainly composed of carbon powder and fluororesin. It is preferable that the ratio of the carbon powder with respect to the fluororesin of the intermediate | middle layer 3 is 20-900 mass%.

  As the carbon powder, a powdery carbon material having an average primary particle size of less than 1 μm can be used. The carbon powder preferably has high electron conductivity. For example, carbon black such as acetylene black and furnace black, activated carbon, and the like can be used. The fluororesin serves as a water repellent for imparting water repellency to the intermediate layer 3 and as a binder for forming the intermediate layer 3.

  As the fluororesin of the intermediate layer 3, it is preferable to use a fluororesin that does not have an ion exchange group in order to prevent flooding due to generated water during the PEFC operation. As this fluororesin, the same fluororesin as the base material layer 1 can be used. Moreover, like the base material layer 1, this fluororesin is particularly preferably a tetrafluoroethylene-hexafluoropropylene copolymer (FEP).

  From the above, the first embodiment is a gas diffusion layer for a polymer electrolyte fuel cell provided on the surface of the catalyst layer, and a fluororesin is formed near the surface of the base material layer 1 made of carbon paper containing carbon fibers. The resin layer 2 containing as a main component is formed, and the intermediate layer 3 containing carbon powder and fluororesin is formed on the surface of the resin layer 2. And in the gas diffusion layer, the ratio of the carbon powder to the fluororesin in the resin layer 2 is lower than the ratio of the carbon powder to the fluororesin in the intermediate layer 3, and the carbon fiber contained in the base material layer 1 is the resin layer 2. And is in contact with the intermediate layer 3.

  In the first embodiment, since the carbon fiber 4 contained in the base material layer 1 penetrates the resin layer 2 and is in contact with the intermediate layer 3, even if the ratio of the carbon powder to the fluororesin of the resin layer 2 is reduced. In addition, water repellency and binding properties can be enhanced while maintaining electronic conductivity. The ratio of the carbon powder with respect to the fluororesin of the resin layer 2 can be reduced to 0%.

Second Embodiment About Manufacturing Method of Gas Diffusion Layer for Solid Polymer Fuel Cell
The second embodiment is the manufacturing method of the first embodiment. In the first embodiment, a molded product obtained by laminating an intermediate layer 3 containing carbon powder and a fluororesin on the surface of the base material layer 1 (hereinafter referred to as “molded product”, see FIG. 2A). It can be manufactured through a process of including a fluororesin (hereinafter, from step S5 to S9). In the second embodiment, the most important part in terms of technical significance is a layer in which a large amount of fluororesin is supported at the boundary between the base material layer and the intermediate layer of the molded product by steps S5 to S9, that is, the resin. Layer 2 is formed.

  FIG. 3 is a diagram showing a process of manufacturing a gas diffusion layer for a polymer electrolyte fuel cell. First, carbon powder, a solvent, and FEP dispersion are mixed with a stirrer to produce an intermediate layer paste (step S1). The FEP dispersion is a liquid in which fine particles of FEP are dispersed in water. Next, the carbon paper is immersed in a solution containing the FEP dispersion, and the carbon paper is dried. And the intermediate | middle layer paste is apply | coated on the carbon paper (step S2). In step S2, the intermediate layer paste is preferably applied by a blade coating method using an applicator. As another method, it can also carry out by the method of including the said paste in the single side | surface of carbon paper, such as the method of spraying the said paste with a spray, the method of apply | coating with a brush. In addition, since the method of immersing carbon paper in an intermediate | middle layer paste will lose | disappear the base material layer 1, it is unpreferable. Next, the carbon paper is left to stand in a dryer at 60 ° C. for 30 minutes and dried (step S3). Next, the carbon paper is fired at 330 ° C. for 30 minutes in a nitrogen atmosphere (step S4). The firing step in step S4 is preferably performed at a temperature of 200 ° C. or higher and 350 ° C. or lower, and particularly preferably at a temperature of 230 ° C. or higher and 330 ° C. or lower. The firing step may be performed in an air atmosphere, but is preferably performed in an inert gas atmosphere such as nitrogen and argon. This step S4 can be performed and omitted as necessary. A molded product as shown in FIG. 2A is obtained through steps S1 to S4.

  Next, the molded product is immersed in a solution containing the FEP dispersion, and then the molded product is taken out (step S5). For the solution containing the FEP dispersion, alcohol such as ethanol, methanol, propanol, water, or the like can be used. By changing the amount of the FEP dispersion, the amount of the resin layer can be increased or decreased. In step S5, the purpose is to include a solution containing the FEP dispersion in the molded product. Instead of immersing in the solution containing the FEP dispersion, a method of spraying a liquid with a spray or a method of applying with a brush in step S5. You may do it. Step S5 can also be performed under reduced pressure.

  Next, excess FEP on the surface is removed by pressing the molded product containing the solution containing the FEP dispersion in Step 5 from both sides with a nonwoven fabric or the like (Step S6). Examples of the method for removing FEP include a method of wiping with a water-absorbing material, a method of blowing off with an air current, and a method of wiping with a resin spatula. Next, the molding is left to stand for 30 minutes in a dryer at 60 ° C. and dried (step S7). Here, as a method for removing the solvent from the molded product, there are a method of raising the temperature, a method of reducing the pressure, and a method of replacing the solvent, but a method of lyophilization or standing at room temperature can also be used. Preferably, since the solvent can be removed in a short time, it is preferably removed by drying at 60 ° C. for 30 minutes. By steps S5 to S7, it is possible to prevent the fluororesin from adhering to the surface of the molded product after the treatment, that is, the surface of the gas diffusion layer. Further, steps S5 to S7 are repeated as many times as necessary (step S8). The amount of the fluororesin in the resin layer can be increased by repeating the step S8. Next, the molded product is baked at 330 ° C. for 30 minutes in a nitrogen atmosphere (step S9). A solid layer as shown in FIG. 2B is obtained by providing a resin layer at the boundary between the base material layer and the intermediate layer in the molded product in which the base material layer and the intermediate layer are laminated by steps S1 to S9. A gas diffusion layer for a molecular fuel cell can be produced.

  In 2nd Embodiment, after forming an intermediate | middle layer and a base material layer previously, in order to form a resin layer in the boundary part of an intermediate | middle layer and a base material layer, carbon fiber contained in a base material layer changes a resin layer. A gas diffusion layer penetrating through and in contact with the intermediate layer can be manufactured.

(Example)
Hereinafter, an example will be described as an example of an embodiment of the present invention. First, the following gas diffusion layers were manufactured. And the following single cell is comprised using the gas diffusion layer, the ratio [mass%] of the carbon powder with respect to the fluororesin of an intermediate | middle layer, the decreasing rate [microvolt * h < ^-1 >] of a single cell voltage, a single cell voltage The relationship between [V] and the internal resistance [mΩ · cm ² ] of the single cell was examined and evaluated. Here, the rate of decrease of the single cell voltage refers to the voltage of the single cell that decreases per hour. The internal resistance of a single cell refers to the sheet resistance of the membrane. A single cell is sandwiched between two plates, a constant pressure is applied, and the single cell sheet resistance is measured by a four-terminal four-probe method according to JIS K7194. [MΩ · cm ² ] was measured.

1. Production of Gas Diffusion Layer First, the ratio of the carbon powder to the fluororesin of the intermediate layer is 1200% by mass, 900% by mass, 230% by mass, 40% by mass, and 20% by mass by the following procedures (1) to (3). A gas diffusion layer without a resin layer as shown in FIG. 2A was produced as Samples A, B, C, D, and E.

(1) A mixture of 5.0 g of carbon powder (Vulcan XC-72), 33 g of 2-propanol, 11 g of water, 22 g of DMF (N, N-dimethylformamide), and FEP dispersion (FEP 120 J). Prepare and mix with stirrer to make intermediate layer paste. At this time, the ratio of the carbon powder to the fluororesin of the intermediate layer is determined by the amount of FEP dispersion. When the ratio of the carbon powder to the fluororesin is 1200% by mass, the amount of FEP dispersion is 0.77 g. When the ratio of the carbon powder to the fluororesin is 900% by mass, the amount of the FEP dispersion is 1.0 g, and when the ratio of the carbon powder to the fluororesin is 230% by mass, the amount of the FEP dispersion is 4.0 g. When the ratio of the carbon powder to the fluororesin is 40% by mass, the amount of the FEP dispersion is 23 g. When the ratio of the carbon powder to the fluororesin is 20% by mass, the amount of the FEP dispersion is 46 g. .
(2) Subsequently, on the carbon vapor having a size of 75 mm × 75 mm soaked in 2% FEP solution and dried as a base material layer, the intermediate layer of the above (1) is applied by a blade coating method using an applicator. The paste is applied and left to dry in a dryer at 60 ° C. for 30 minutes.
(3) Then, it is removed from the dryer and baked at 330 ° C. for 30 minutes in a nitrogen atmosphere.

  The conventional gas diffusion layers A, B, C, D, and E having an intermediate layer on the base material layer as shown in FIG. 2A are obtained by the above procedures (1) to (3).

  Next, a resin layer is provided on the gas diffusion layers A, B, C, D, and E according to the following procedures (4) to (7), and the resin layer of this embodiment as shown in FIG. A gas diffusion layer is manufactured. Hereinafter, the gas diffusion layer including the resin layer is distinguished by the following notation.

  FIG. 4 is a diagram showing a table of types of gas diffusion layers. And the ratio of the carbon powder with respect to the fluororesin of an intermediate | middle layer of each gas diffusion layer and the ratio of the carbon powder with respect to the fluororesin of a resin layer are shown with the table | surface. The durability in FIG. 4 shows the voltage drop rate of a single cell due to flooding or peeling of each layer, and the durability, single cell voltage and internal resistance were evaluated in comparison with a gas diffusion layer without a resin layer, respectively. Yes. Here, ◯ indicates good, Δ indicates normal, and-indicates no evaluation.

For example, when a gas diffusion layer A is provided with a resin layer,
When the ratio of the carbon powder to the fluororesin of the resin layer is 45% by mass, the gas diffusion layer is designated as A1,
When the ratio of the carbon powder to the fluororesin of the resin layer is 25% by mass, the gas diffusion layer is designated as A2.
When the ratio of the carbon powder to the fluororesin of the resin layer is 10% by mass, the gas diffusion layer is A3,
When the ratio of the carbon powder to the fluororesin of the resin layer is 0% by mass, the gas diffusion layer is A4.

  The gas diffusion layers B, C, D, and E are also expressed in the same manner. However, the gas diffusion layer D is provided with three resin layers of 45 mass%, 25 mass%, and 10 mass% of the carbon powder with respect to the fluororesin of the resin layer, and the notations thereof are also denoted as D1, D2, and D3, respectively. . In addition, the gas diffusion layer E is provided with two resin layers of 45% and 25% of the ratio of the carbon powder to the fluororesin of the resin layer, and the notations thereof are also denoted as E1 and E2, respectively.

(4) The gas diffusion layers A, B, C, D, and E are immersed in methanol containing 3% FEP dispersion (FEP 120 J) and allowed to stand for 5 minutes.
(5) Then, the gas diffusion layer of (4) is taken out and pressed from both sides with a nonwoven fabric or the like to remove excess FEP on the surface. Then, it is dried at 60 ° C. in the atmosphere.
(6) Repeat (4) and (5) above a predetermined number of times. The predetermined number of times varies depending on the ratio of the carbon powder to the fluororesin in the resin layer. When the number of repetitions is increased, the amount of the fluororesin in the resin layer increases and the ratio of the carbon powder to the fluororesin decreases.
(7) The gas diffusion layer of (6) is baked at 330 ° C. for 30 minutes in a nitrogen atmosphere.

  By the above procedures (4) to (7), the gas diffusion layers A1 to A4 of the present invention having the resin layer as shown in FIG. 2B, B1 to B4, C1 to C4, D1 E1 and E2 are obtained from D3.

Further, according to the following procedures (8) to (12), the base material layer, the resin layer, and the intermediate layer are arranged in this order, and the carbon fiber of the base material layer and the intermediate layer are not in contact with each other. A gas diffusion layer was produced. A resin layer contains a fluororesin and the ratio of the carbon powder with respect to a fluororesin is 10 mass%, 25 mass%, or 45 mass%. The intermediate layer includes carbon powder and a fluororesin, and the ratio of the carbon powder to the fluororesin is 230% by mass.
(8) Prepare a mixture of 5.0 g of carbon powder (Vulcan XC-72), 33 g of 2-propanol, 11 g of water, 22 g of DMF, and FEP dispersion (FEP 120 J), and mix with a stirrer. Make an intermediate paste. At this time, the ratio of the carbon powder to the fluororesin of the intermediate layer manufactured using the intermediate paste is determined by the amount of the FEP dispersion. When the ratio of the carbon powder to the fluororesin is 230% by mass, the FEP dispersion When the amount of carbon powder is 1.0 g and the ratio of the carbon powder to the fluororesin is 45% by mass, when the amount of FEP dispersion is 21 g and the ratio of the carbon powder to the fluororesin is 25% by mass, the FEP dispersion When the amount of the carbon powder is 37 g and the ratio of the carbon powder to the fluororesin is 10% by mass, the amount of the FEP dispersion is 93 g. In this example, the intermediate layer paste is also used as a material for the resin layer.
(9) Subsequently, on the carbon paper having a size of 75 mm × 75 mm soaked in a 2% FEP solution as a base material layer and dried, a blade coating method using an applicator is applied to the fluororesin of (8) above. An intermediate layer paste having a carbon powder ratio of 10% by mass, 25% by mass, and 45% by mass is applied, and left to stand in a dryer at 60 ° C. for 30 minutes for drying.
(10) Then, it is removed from the dryer and baked at 330 ° C. for 30 minutes in a nitrogen atmosphere. Thereby, a base material layer is each provided with the resin layer whose ratio of the carbon powder with respect to a fluororesin is 10 mass%, 25 mass%, and 45 mass%.
(11) Further, an intermediate layer paste in which the ratio of the carbon powder to the fluororesin of (8) is 230% by mass is applied onto the resin layer by a blade coating method using an applicator, and a dryer at 60 ° C. Left to dry for 30 minutes.
(12) Then, it is removed from the dryer and baked at 330 ° C. for 30 minutes in a nitrogen atmosphere. Thereby, the laminated body of a base material layer and a resin layer is each provided with the intermediate | middle layer whose ratio of the carbon powder with respect to a fluororesin is 230 mass%.

  By the above procedures (8) to (12), a resin layer having a high water repellency and an intermediate layer having a lower water repellency than the resin layer are provided on the base material layer as shown in FIG. The gas diffusion layer 10c is manufactured. The gas diffusion layers in which the ratio of the carbon powder to the fluororesin of the resin layer is 10% by mass, 25% by mass, and 45% by mass are defined as C12, C13, and C14.

2. Manufacture of a single cell Next, the single cell was manufactured with the following procedures using the gas diffusion layer manufactured by the said procedure.
(1) A mixture of 3.0 g of platinum-supported carbon (TEC10E-50E manufactured by Tanaka Kikinzoku) and 21 g of a solid quotient molecular electrolyte solution (manufactured by Aldrich, Nafion 5% by mass solution) is prepared with a propeller type agitator. Mix to make catalyst paste.
(2) On the gas diffusion layer produced by the above procedure, the above 2. is obtained by a blade coating method using an applicator. The catalyst paste of (1) is applied. Thereby, an electrode is obtained.
(3) 2. The slit width of the applicator is adjusted so that the amount of platinum supported on the electrode of (2) is 0.5 mg · cm ⁻² .
(4) Further, the above 2. The electrode of (3) is cut to a size of 25 cm ² , and the two electrodes are joined to both surfaces of a solid polymer membrane (manufactured by Nafion 112 Dupont) by heat-pressing at 135 ° C. In this heating and pressure welding, the thickness of the electrode is reduced by 25% using a spacer. Thereby, MEA is obtained.
(5) 2. (4) MEA is sandwiched between separators. Thereby, a single cell is obtained.

3. Experiment Next, air and hydrogen were supplied to the single cell manufactured by the above procedure, and the continuous operation was performed at a current density of 300 [mA · cm ⁻² ], and the ratio of the carbon powder to the fluororesin of the intermediate layer [mass% ], The decrease rate of the single cell voltage [μV · h ⁻¹ ], the single cell voltage [V], and the internal resistance [mΩ · cm ² ] of the single cell were examined.

FIG. 5 is a diagram showing the relationship between the ratio [% by mass] of the carbon powder to the fluororesin of the intermediate layer and the rate of decrease of the single cell voltage [μV · h ⁻¹ ], and the voltage drop of the single cell in the continuous operation test. Indicates the rate. In addition, the ratio of the carbon powder with respect to the fluororesin of the intermediate | middle layer of a horizontal axis is represented by the logarithm. From FIG. 5, the voltage drop rate [μV · h ⁻¹ ] of the single cell including the gas diffusion layer including the resin layer, which is the gas diffusion layer of the present invention, is a gas diffusion layer not including the conventional resin layer. It can be seen that it is significantly lower than the single cell used. This is a result of being able to suppress a decrease in cell voltage due to flooding since high water repellency was imparted by using the gas diffusion layer of the present invention. In particular, it can be seen that the single cell voltage drop rate is remarkably small when a gas diffusion layer in which the ratio of the carbon powder to the fluororesin of the resin layer is less than 25% by mass is used. This is because the effect of suppressing flooding is remarkably enhanced as a result of the remarkable improvement in water repellency by the ratio of the carbon powder to the fluororesin being less than 25% by mass. Moreover, when the ratio of the carbon powder with respect to the fluororesin of an intermediate | middle layer is used for the gas diffusion layer whose mass ratio is 1200 mass%, it turns out that the cell voltage fall rate is high compared with the ratio of 900 mass% or less. This is presumably because the ratio of the carbon powder to the fluororesin in the intermediate layer was too high, and the current density distribution became non-uniform due to the decrease in the mechanical strength of the intermediate layer.

Subsequently, the current I-voltage V characteristics and the electrical internal resistance of the cell using the gas diffusion layer shown in FIG. 4 were measured. FIG. 6 is a diagram showing the relationship between the ratio [mass%] of the carbon powder to the fluororesin of the intermediate layer and the single cell voltage [V]. FIG. 7 is a graph showing the relationship between the ratio [%] of the carbon powder to the fluororesin of the intermediate layer and the internal resistance [mΩ · cm ² ] of the single cell. Both FIG. 6 and FIG. 7 show the voltage and the internal resistance of the single cell at a current density of 300 [mA · cm ⁻² ]. In both FIG. 6 and FIG. 7, the ratio of the carbon powder to the fluororesin in the intermediate layer on the horizontal axis is expressed in logarithm. FIG. 6 shows that the voltage of the single cell using the gas diffusion layer in which the ratio of the carbon powder to the fluororesin of the intermediate layer is less than 40% by mass is extremely low. Further, FIG. 7 shows that the single cell using the gas diffusion layer in which the ratio of the carbon powder to the fluororesin in the intermediate layer is smaller than 40% by mass has a remarkably high internal resistance. As can be seen from these results, the single cell using the gas diffusion layer in which the ratio of the carbon powder to the fluororesin in the intermediate layer is less than 40% by mass is due to the large amount of fluororesin in the intermediate layer. As the resistance increased, the internal resistance of the single cell increased and the single cell voltage decreased. Furthermore, it can be seen from FIGS. 6 and 7 that the ratio of the carbon powder to the fluororesin in the resin layer does not affect the single cell voltage and the internal resistance. This is because the gas diffusion layer of the present invention is electrically conductive even if the ratio of the carbon powder to the fluororesin in the resin layer decreases because the carbon fibers contained in the base material layer penetrate the resin layer and contact the intermediate layer. The fact that the resistance does not change indicates that the single cell voltage is not affected.

Furthermore, the IV characteristics and electrical internal resistance of the cell using the gas diffusion layer shown in FIG. 8 were measured. 9 and 10 show the ratio of the carbon powder to the fluororesin of the resin layer [mass%], the single cell voltage [V] and the internal resistance [mΩ · cm ² ] at a current density of 300 [mA · cm ⁻² ]. It is a figure which shows a relationship. From FIG. 9, when the gas diffusion layer of the present invention is used, the ratio of the carbon powder to the fluororesin of the resin layer does not affect the single cell voltage, whereas the conventional gas diffusion layer is used. It can be seen that the single cell voltage significantly decreases as the ratio decreases. From FIG. 10, when the gas diffusion layer of the present invention is used, the ratio of the carbon powder to the fluororesin of the resin layer does not affect the internal resistance of the single cell, whereas the conventional gas diffusion layer is used. As shown, the internal resistance of the single cell increases remarkably as the ratio decreases. From these results, when the ratio of the carbon powder to the fluororesin of the resin layer is decreased in order to improve water repellency and binding properties, the base layer and the intermediate layer are in contact with each other in the gas diffusion layer of the present invention. Therefore, in the conventional gas diffusion layer, it was confirmed that the resin layer works as an insulator and the single cell voltage decreases as a result of the increase in the internal resistance.

(Summary)
From the above results, the gas diffusion layer for the polymer electrolyte fuel cell of the present embodiment increases the water repellency of the gas diffusion layer without increasing the electrical internal resistance of the single cell, thereby improving the durability performance of the PEFC. It was confirmed that it can be improved. In particular, in the gas diffusion layer, when the ratio of the carbon powder to the fluororesin of the intermediate layer is 20 to 900% by mass and the ratio of the carbon powder to the fluororesin of the resin layer is 25% by mass or less, the diffusion layer is It was confirmed that the output characteristics and durability of the single cell used were remarkably excellent.

  According to the present invention, since the durability is improved while maintaining the cell voltage of the conventional PEFC, a highly reliable PEFC having an energy saving effect can be obtained. In particular, these PEFCs are expected to be used in a wide range of fields, from small business use to home use, portable use, and in-vehicle use. The industrial applicability is extremely high.

DESCRIPTION OF SYMBOLS 1 Base material layer 2 Resin layer 3 Intermediate layer 4 Carbon fiber 5 Catalyst layer 10a The conventional gas diffusion layer 10b without a resin layer The resin layer was provided, and the gas diffusion layer 10c with which the carbon fiber contacted the intermediate layer was provided with the resin layer Conventional gas diffusion layer 11 Electrolyte membrane 12a Anode gasket 12b Cathode gasket 13 Electrode 13a Anode (negative electrode)
13b Cathode (positive electrode)
14a Anode side separator 14b Cathode side separator 15 Flow path 16 MEA
20 single cell (unit battery)

Claims (6)

A base material layer containing carbon fiber, a resin layer containing fluororesin, and an intermediate layer containing carbon powder and fluororesin is a gas diffusion layer used for an electrode of a polymer electrolyte fuel cell arranged in this order,
The ratio of the carbon powder to the fluororesin of the resin layer is lower than the ratio of the carbon powder to the fluororesin of the intermediate layer, and
A gas diffusion layer characterized in that carbon fibers contained in the base material layer pass through the resin layer and come into contact with the intermediate layer. 2. The gas diffusion layer according to claim 1, wherein a ratio of the mass of the carbon powder to the fluororesin of the intermediate layer is 20% by mass or more and 900% by mass or less. The gas diffusion layer according to claim 1 or 2, wherein the fluororesin of the resin layer and the intermediate layer contains a tetrafluoroethylene-hexafluoropropylene copolymer (FEP). A method for producing a gas diffusion layer used for an electrode of a polymer electrolyte fuel cell, comprising:
Including an intermediate layer paste containing at least carbon powder and a fluororesin on a base material layer made of carbon fiber, and drying (S2, S3);
Firing the intermediate layer (S4);
A step of attaching a solution containing a fluororesin to a laminate comprising the base material layer and the fired intermediate layer (S5);
Removing excess solution adhering to the surface of the laminate (S6);
A step (S7) of drying the laminate through the step (S6);
The manufacturing method of the gas diffusion layer which comprises the process (S9) baked after that. Attaching a solution containing a fluororesin to the laminate (S5);
Removing excess solution adhering to the surface of the laminate (S6);
The method for producing a gas diffusion layer according to claim 4, wherein the step (S7) of drying the laminate that has undergone the step (S6) is repeated a predetermined number of times. The intermediate layer paste containing the carbon powder and the fluororesin and the fluororesin in the solution containing the fluororesin contain a tetrafluoroethylene-hexafluoropropylene copolymer (FEP). 5. A method for producing a gas diffusion layer according to 5.

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