JP2013175384A - Method for manufacturing porous electrode base material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method capable of improving a carbonization yield without depending on a resin component to be mixed in paper making even having a carbonization process, the method capable of a porous carbon electrode base material with high electrical conductivity.SOLUTION: The method of manufacturing a porous carbonaceous electrode base material comprises: the step (1) of manufacturing a paper body in which short carbon fibers (A), short carbon fiber precursor fibers (b) and/or fibril-like fibers(b') are dispersed; the step (2) of heat-treating the paper body for 10-300 seconds at 300-450°C under an oxygen environment to obtain a precursor sheet of a porous electrode base material; and the step (3) of carbonizing the precursor sheet obtained in the step (2) at 2000-3000°C under a nitrogen atmosphere to manufacture the porous carbonaceous electrode base material.

Description

  The present invention relates to a method for producing a porous electrode substrate used in a polymer electrolyte fuel cell.

  A polymer electrolyte fuel cell is an apparatus that obtains an electromotive force by electrochemically reacting a fuel gas such as hydrogen and an oxidizing gas such as oxygen. The polymer electrolyte fuel cell includes a hydrogen ion (proton). And a polymer electrolyte membrane that selectively conducts. Further, two sets of gas diffusion electrodes each having a catalyst layer mainly composed of carbon powder carrying a noble metal catalyst and a gas diffusion electrode substrate are joined to both surfaces of the polymer electrolyte membrane.

  Such a joined body composed of a polymer electrolyte membrane and two sets of gas diffusion electrodes is called a membrane-electrode assembly (MEA). Further, on both outer sides of the MEA, separators are provided in which gas flow paths for supplying fuel gas or oxidizing gas and for discharging generated gas and excess gas are formed.

  The gas diffusion electrode substrate is mainly required to have the following three functions. The first function is a function of uniformly supplying the fuel gas or the oxidizing gas to the noble metal-based catalyst in the catalyst layer from the gas flow path formed in the separator disposed outside the first function. The second function is a function of discharging water generated by the reaction in the catalyst layer. The third function is a function of conducting electrons necessary for the reaction in the catalyst layer or electrons generated by the reaction in the catalyst layer to the separator. As a base material satisfying these functions, a base material having a porous structure made of a carbonaceous material is usually used. Specifically, substrates using carbon fibers such as carbon paper, carbon fiber cloth, carbon fiber felt, etc. are generally used. These base materials are not only highly conductive due to carbon fibers, but are porous materials, and are therefore suitable materials for gas diffusion layers because of high permeability of liquids such as fuel gas and generated water.

  As a general method for producing carbon paper, carbon short fibers and binder components such as carbon fiber precursor fibers are made and then bound with an organic polymer, which is baked at a high temperature to carbonize the organic polymer. There is known a method for producing a paper-like carbon / carbon composite. The carbon fiber precursor fiber or resin composition to be carbonized in the production process generally has a very high weight reduction rate of 50 to 70%, which is a production process with a very large energy cost and environmental load. Furthermore, from the viewpoint of increasing the conductivity, mechanical strength and thermal conductivity of the carbon paper after carbonization, it is necessary to increase the bulk density of the carbon paper. There is a vicious cycle of increasing load and energy costs. For example, Patent Document 1 discloses a method for producing a gas diffusion electrode substrate using a resin composition having a relatively high carbonization yield of 40% or more as a raw material. Patent Document 2 discloses a gas diffusion electrode that does not require a conventional baking process at a high temperature.

  However, in the method of Patent Document 1, the resin composition used as a raw material is limited, and the carbonization yield of thermoplastic resin particles and the like to be mixed other than the resin composition is as low as 20% or less. The carbonization yield of the entire sheet in the process tends to be low. In addition, the method of Patent Document 2 is a structure in which carbon powder is only bound by a resin component, and therefore has a problem that electric conductivity and mechanical strength are lower than carbon paper which is a conventional C / C composite. was there.

JP 2011-146373 A Japanese Patent No. 4828864

  The present invention overcomes the problems as described above and is a production method having a carbonization step, but is a production method capable of improving the carbonization yield without being influenced by the resin component to be mixed, And it aims at providing the method which can manufacture a porous carbon electrode base material with high electrical conductivity.

  Specifically, the above problems are solved by the following inventions [1] to [6].

[1] A method for producing a porous carbonaceous electrode substrate including the following steps.
Step (1): A step of producing a paper body in which short carbon fibers (A), carbon fiber precursor short fibers (b) and / or fibrillar fibers (b ′) are dispersed.
Step (2): A step of subjecting the paper body to a heat treatment at 300 to 450 ° C. for 10 to 300 seconds in an oxygen atmosphere to obtain a porous electrode substrate precursor sheet.
Step (3): A step of producing a porous carbonaceous electrode substrate by carbonizing the precursor sheet obtained in the step (2) at 2000 to 3000 ° C. in a nitrogen atmosphere.
When the papermaking body in the step (1) does not include the fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b′-1), between the step (1) and the step (2), There is a step (4) of impregnating the papermaking body with a thermosetting resin, followed by drying and molding.

  [2] The production method according to the above [1], comprising a step (4) of impregnating the papermaking body with a thermosetting resin between the step (1) and the step (2), followed by drying and molding.

  [3] When the process (4) is included between the process (1) and the process (2), the process (5) includes the process (5) of confounding the paper body between the processes (1) and (4). The production method according to [1].

  [4] The production method according to [2], further including a step (5) of tangling the paper body between the step (1) and the step (4).

  [5] The production method according to any one of [1] to [4], wherein the heat treatment method in the step (3) is heating by far infrared rays.

  [6] The manufacturing method according to any one of [1] to [4], wherein the heat treatment method in the step (3) is contact-type heating using an induction heating roll.

Although the method for producing a porous carbon electrode substrate of the present invention is a production method having a carbonization step, the production cost can be improved because the carbonization yield can be improved without being influenced by the resin component to be mixed. A porous carbon electrode substrate with high electrical conductivity can be provided at a low cost.

  Hereinafter, the present invention will be described in detail.

  As a porous carbon electrode substrate for a polymer electrolyte fuel cell, there is a paper body made up of a plurality of short carbon fibers having high surface smoothness, good electrical contact, and high mechanical strength. preferable. Hereinafter, the production method of the present invention will be described for each step.

Step (1): A step of producing a paper body in which short carbon fibers (A), carbon fiber precursor short fibers (b) and / or fibrillar fibers (b ′) are dispersed <carbon short fibers (A)>
The short carbon fiber (A) can be used regardless of the raw material, but is selected from polyacrylonitrile (hereinafter abbreviated as PAN) carbon fiber, pitch carbon fiber, rayon carbon fiber, and phenolic carbon fiber. It is preferable to include one or more carbon fibers, and it is more preferable to include PAN-based carbon fibers or pitch-based carbon fibers.

  The average diameter of the short carbon fibers (A) is preferably about 3 to 30 μm, more preferably 4 to 20 μm, and even more preferably 4 to 8 μm, from the viewpoint of surface smoothness and conductivity as a gas diffusion layer.

  The length of the short carbon fibers (A) is preferably 2 to 12 mm, more preferably 3 to 9 mm, from the viewpoint of dispersibility during papermaking and mechanical strength as a gas diffusion layer.

<Carbon fiber precursor short fiber (b)>
The carbon fiber precursor short fiber (b) is obtained by cutting a carbon fiber precursor fiber having a long fiber shape into an appropriate length. The fiber length of the carbon fiber precursor short fiber (b) is preferably about 2 to 20 mm from the viewpoint of dispersibility. Although the cross-sectional shape of the carbon fiber precursor short fiber (b) is not particularly limited, a high roundness is preferable from the viewpoint of mechanical strength after carbonization and production cost. The diameter of the carbon fiber precursor short fiber (b) is preferably 5 μm or less in order to suppress breakage due to shrinkage during carbonization.

  As a polymer used as such a carbon fiber precursor short fiber (b), it is preferable that the residual mass in the carbonization treatment step is 20% by mass or more. Examples of such polymers include acrylic polymers, cellulose polymers, and phenolic polymers.

  The acrylic polymer used for the carbon fiber precursor short fiber (b) may be a homopolymer of acrylonitrile or a copolymer of acrylonitrile and other monomers. The monomer copolymerized with acrylonitrile is not particularly limited as long as it is an unsaturated monomer constituting a general acrylic fiber. For example, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, Acrylic esters represented by 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, hydroxypropyl acrylate, etc .; methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, methacrylic acid Typical examples include t-butyl acid, n-hexyl methacrylate, cyclohexyl methacrylate, lauryl methacrylate, 2-hydroxyethyl methacrylate, hydroxypropyl methacrylate, diethylaminoethyl methacrylate and the like. Methacrylic acid esters; acrylic acid, methacrylic acid, maleic acid, itaconic acid, acrylamide, N-methylol acrylamide, diacetone acrylamide, styrene, vinyl toluene, vinyl acetate, vinyl chloride, vinylidene chloride, vinylidene bromide, vinyl fluoride, And vinylidene fluoride.

  When considering the spinnability and the short carbon fibers (A) from low temperature to high temperature, the remaining mass at the time of carbonization is large, and the fiber elasticity and fiber strength when performing the entanglement treatment described below, It is preferable to use an acrylic polymer containing 50% by mass or more of acrylonitrile units. Accordingly, the carbon fiber precursor fiber (b) is preferably an acrylic fiber or an acrylic fiber (containing 50% by mass or more of acrylonitrile units).

  The weight average molecular weight of the acrylonitrile-based polymer used for the carbon fiber precursor short fiber (b) is not particularly limited, but is preferably 50,000 to 1,000,000. When the weight average molecular weight is 50,000 or more, the spinnability is improved and the yarn quality of the fiber tends to be good. When the weight average molecular weight is 1,000,000 or less, the polymer concentration that gives the optimum viscosity of the spinning dope increases, and the productivity tends to improve.

  One type of carbon fiber precursor short fiber (b) may be used, or two or more types of carbon fiber precursor short fibers (b) having different fiber diameters and polymer types may be used.

<Fibrous fiber (b ')>
As the fibrillar fiber (b ′), any fiber can be used regardless of whether it is a natural fiber or a synthetic fiber. For example, it includes fibrillar carbon precursor (b′-1) mainly composed of acrylic or the like to wood pulp which is a natural fiber. Among these, since it is preferable that the metal content is small, the fibrillar fiber (b ′) is preferably a synthetic fiber. More preferably, a fibrillar carbon precursor fiber (b′-1) or the like can be used. These may be used alone or in combination. Moreover, in order to improve a carbonization yield, it is preferable to use the fibrillar carbon precursor fiber (b′-1) shown below.

  The fibrillar carbon precursor fiber (b′-1) is a long-fiber, easily splittable sea-island composite fiber cut to an appropriate length, and is beaten by a refiner, a pulper, or the like to be fibrillated. The fibrillar carbon precursor fiber (b′-1) is produced using two or more kinds of different polymers that are dissolved in a common solvent and are incompatible, and at least one kind of polymer is carbonized. The residual mass in the process is preferably 20% by mass or more.

  Among the polymers used for the easily splittable sea-island composite fibers, those having a residual mass of 20% by mass or more in the carbonization treatment include acrylic polymers, cellulose polymers, and phenol polymers. Among them, it is preferable to use an acrylic polymer containing 50% by mass or more of an acrylonitrile unit from the viewpoint of spinnability and the remaining mass in the carbonization treatment step.

  The acrylic polymer may be obtained by homopolymerizing acrylonitrile or copolymerizing acrylonitrile and other monomers. The monomer copolymerized with acrylonitrile is not particularly limited as long as it is an unsaturated monomer constituting a general acrylic fiber. For example, methyl acrylate, ethyl acrylate, isopropyl acrylate, n-butyl acrylate, Acrylic esters represented by 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, hydroxypropyl acrylate, etc .; methyl methacrylate, ethyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, methacrylic acid Typical examples include t-butyl acid, n-hexyl methacrylate, cyclohexyl methacrylate, lauryl methacrylate, 2-hydroxyethyl methacrylate, hydroxypropyl methacrylate, diethylaminoethyl methacrylate and the like. Methacrylic acid esters; acrylic acid, methacrylic acid, maleic acid, itaconic acid, acrylamide, N-methylol acrylamide, diacetone acrylamide, styrene, vinyl toluene, vinyl acetate, vinyl chloride, vinylidene chloride, vinylidene bromide, vinyl fluoride, And vinylidene fluoride.

  Although the weight average molecular weight of an acrylonitrile-type polymer is not specifically limited, 50,000-1 million are preferable. When the weight average molecular weight is 50,000 or more, the spinnability is improved and the yarn quality of the fiber tends to be good. When the weight average molecular weight is 1,000,000 or less, the polymer concentration that gives the optimum viscosity of the spinning dope increases, and the productivity tends to improve.

  Among the polymers used for the easily splittable sea-island composite fibers, when the above-mentioned acrylic polymer is used as a polymer having a residual mass of 20% by mass or more in the carbonization treatment process, the other polymer is acrylonitrile. When dissolved in the same solvent as the base polymer and used as a spinning dope, it must be stable. In other words, in the spinning dope, if the two polymers have a high degree of incompatibility, the fibers become inhomogeneous and cause yarn breakage during spinning, so the fibers may not be shaped. is there. Therefore, other polymers are incompatible with acrylonitrile polymers when dissolved in the same solvent as acrylonitrile polymers, but they must be miscible enough to form a sea-island structure during spinning. . In addition, when wet spinning is performed, if another polymer is dissolved in water in the coagulation tank and the washing tank, the polymer falls off and is a manufacturing problem. Therefore, the other polymer needs to be hardly soluble in water.

  Examples of other polymers that satisfy these requirements include polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, polyvinyl pyrrolidone, cellulose acetate, acrylic resin, methacrylic resin, and phenol resin. Resin and methacrylic resin can be preferably used in terms of the balance of the above-mentioned requirements. The other polymer may be one type or two or more types.

  The splittable sea-island composite fiber used as the fibrillar carbon precursor fiber (b′-1) can be produced by a normal wet spinning method. When an acrylonitrile-based polymer is used assuming that the residual mass in the carbonization process is 20% by mass or more, the polymer is mixed with another polymer, dissolved in a solvent, and then an easily splittable sea-island composite fiber. And Alternatively, a spinning stock solution obtained by dissolving an acrylonitrile-based polymer in a solvent and a spinning stock solution obtained by dissolving another polymer in a solvent are mixed with a static mixer or the like, and a spinning stock solution of an easily splittable sea-island composite fiber. It is good. As the solvent, organic solvents such as dimethylamide, dimethylformamide, dimethyl sulfoxide and the like can be used. These split spinning solutions are spun from a nozzle and subjected to wet heat drawing, washing, drying and dry heat drawing, whereby an easily split sea-island composite fiber can be obtained.

  The cross-sectional shape of the fibrillar fiber (b ′) is not particularly limited. In order to suppress dispersibility and breakage due to shrinkage at the time of carbonization, the fineness of the fibrillar fiber (b ′) is preferably 1 to 10 dtex. The average fiber length of the fibrillar fibers (b ′) is preferably 1 to 20 mm from the viewpoint of dispersibility.

<Manufacture of paper bodies>
As a method for producing a paper body in which the short fiber (A) and the carbon fiber precursor fiber (b) and / or the fibrillar fiber (b ′) are dispersed, the carbon short fiber (A) in a liquid medium, Wet method in which carbon fiber precursor fibers (b) and / or fibrillar fibers (b ′) are dispersed to make paper, carbon short fibers (A) in the air, carbon fiber precursor fibers (b) and / or A paper making method such as a dry method in which the fibrillar fibers (b ′) are dispersed and accumulated can be applied. However, it is preferable to use a wet method from the viewpoint of high uniformity of the paper body.

  The mixing ratio of the carbon short fiber (A), the carbon fiber precursor fiber (b) and / or the fibrillar fiber (b ′) is 100 parts by weight of the carbon short fiber (A), and the carbon fiber precursor fiber ( It is preferable to mix so that the total amount of b) and a fibrillar fiber (b ') may be 20-100 weight part. When the total amount of the carbon fiber precursor fiber (b) and the fibrillar fiber (b ′) is small, the strength of the papermaking body is lowered, and the total amount of the carbon fiber precursor fiber (b) and the fibrillar fiber (b ′) is large. As a result, the electrical conductivity of the resulting porous electrode substrate is lowered. The ratio of the carbon fiber precursor fiber (b) to the fibrillar fiber (b ′) is 25 to 100 parts by weight of the fibrillar fiber (b ′) with respect to 100 parts by weight of the carbon fiber precursor fiber (b). It is preferable that it is contained in the ratio.

  Carbon fiber precursor fibers (b) and / or fibrillar fibers (b) are also used to help the short carbon fibers (A) open into single fibers and prevent the opened single fibers from refocusing. ´) is used. Further, if necessary, wet papermaking can be performed using a binder.

  A binder has a role as a glue which connects each component in the precursor sheet | seat containing a carbon short fiber (A) and a carbon precursor fiber (b). As the binder, polyvinyl alcohol (PVA), polyvinyl acetate, or the like can be used. In particular, polyvinyl alcohol is preferable because it has excellent binding power in the paper making process and the short carbon fibers (A) are less dropped. In the present invention, it is also possible to use the binder in a fiber shape.

  In the present invention, even if papermaking is performed without using a binder, an appropriate entanglement between the short carbon fiber (A) and the carbon fiber precursor fiber (b) and / or the fibrillar fiber (b ′) can be obtained. .

  Examples of the liquid medium in which the carbon short fibers (A) and the carbon fiber precursor fibers (b) and / or the fibrillar fibers (b ′) are dispersed include carbon precursor fibers (b) such as water and alcohol. Media that do not. Among these, it is preferable to use water from a viewpoint of productivity.

  It is preferable to use a medium such as water at a rate that the fiber concentration in the slurry in which the fiber is dispersed is about 1 to 50 g / L. If the fiber concentration in the slurry is low, the papermaking speed has to be slowed down, resulting in poor productivity, and if the fiber concentration is too high, the dispersibility of the fiber in the slurry is reduced. A lump is easily generated, and a papermaking body with large unevenness in weight per unit area is obtained.

  Examples of the method of mixing the short carbon fiber (A) and the carbon fiber precursor fiber (b) and / or the fibrillar fiber (b ′) include a method of stirring and dispersing in water and a method of directly mixing them. From the viewpoint of uniformly dispersing, a method of diffusing and dispersing in water is preferable. The strength of the papermaking body is improved by mixing the short carbon fibers (A), the carbon fiber precursor fibers (b) and / or the fibrillar fibers (b ′), and making paper to produce a papermaking body. Can do. Moreover, it can prevent that the carbon short fiber (A) peels from a precursor sheet | seat during the manufacture, and the orientation of a carbon short fiber (A) changes.

  The paper body can be produced by either a continuous method or a batch method, but it is preferably produced by a continuous method from the viewpoint of the productivity and mechanical strength of the paper body.

The basis weight of the paper body is preferably 10 g / m ² or more and 200 g / m ² or less from the viewpoints of handling properties of the paper body and gas permeability, conductivity, and handling properties when used as a porous electrode substrate. Further, the thickness of the paper body is preferably 20 μm or more and 400 μm or less.

Step (2): The paper body is subjected to heat treatment at 300 to 450 ° C. for 10 to 300 seconds in an oxygen atmosphere to obtain a porous carbonaceous electrode substrate precursor sheet <Heat treatment>
The paper body is heat-treated at a temperature of 300 to 450 ° C. for 10 to 300 seconds to obtain a porous electrode base material precursor sheet. This heat treatment improves the carbonization yield of the carbon fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b′-1) and / or the thermosetting resin described later. Specifically, the carbon fiber precursor short fibers (b) and / or the fibrillar carbon precursor fibers (b′-1) and / or the thermosetting resin to be described later are fused to the carbon short fibers (A). The carbon fiber precursor short fibers (b) and / or fibrillar carbon not only promotes and strengthens the binding structure of the short carbon fibers (A) formed by molding in the step (4) described later. The surface state of the precursor fiber (b′-1) and / or the thermosetting resin described later is modified. The carbon fiber precursor short fiber (b) and / or the fibrillated carbon precursor fiber (b′-1) and / or the modified surface of the thermosetting resin described later is the carbon fiber precursor short fiber (b). And / or fibrillar carbon precursor fiber (b′-1) and / or the entire thermosetting resin described later, and serves as a protective film during carbonization, so that the carbon fiber precursor Short body fibers (b) and / or fibrillar carbon precursor fibers (b'-1) and / or the weight loss inside the thermosetting resin described later can be prevented, and the carbonization yield can be greatly improved. . The carbonization yield of the carbon fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b′-1) and / or the thermosetting resin described later can be improved. The heat treatment is preferably performed in an atmosphere where oxygen is abundant, for example, in the air. This is because the temperature at which the heat treatment is performed is 300 to 450 ° C., and if it is too low, the oxidation reaction does not proceed, and if it is too high, the carbonization reaction occurs.

  A continuous heat treatment by continuous or intermittent direct pressure heating using a heating roll or the like, or a non-contact heating method by far infrared rays, hot air, or the like can be used. Even if any method is used, the carbon short fiber (A) and the carbon fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b ′) can be fused. Because the short fiber has high infrared absorption efficiency, oxidation and cyclization reactions can be efficiently performed in a short time, so far-infrared heating method is required to obtain a high-performance porous carbon electrode substrate at a lower cost. Is preferably used.

  Further, the heat treatment time is 10 to 300 seconds, but from the viewpoint of productivity and production cost, it is preferable to produce a porous carbon electrode substrate by a continuously short process, and it is preferably 30 to 120 seconds. More preferred. When heat-treating a continuously produced sheet, it is preferable to carry out continuously over the entire length of the sheet. As a result, the carbonization treatment can be performed continuously, and the productivity of the porous electrode substrate, the membrane-electrode assembly and the fuel cell can be improved and the manufacturing cost can be reduced.

  The amount of heat necessary for the heat treatment can be simply expressed by the product of the temperature applied to the paper body and the time. Specifically, in order to improve the carbonization rate, the product of the heat treatment temperature and the heat treatment time is preferably 3000 to 135000 ° C. · second, more preferably 9000 to 54000 ° C. · second.

Step (3): A step of producing a porous carbonaceous electrode substrate by carbonizing the precursor sheet obtained in the step (2) at 2000 to 3000 ° C. in a nitrogen atmosphere .

<Carbonization>
The carbonization treatment carbonizes the carbon fiber precursor short fibers (b) and / or the fibrillar carbon precursor fibers (b ′) and the thermosetting resin in the precursor sheet. The carbonization treatment is preferably performed in an inert gas in order to increase the conductivity of the porous electrode substrate. The carbonization treatment is usually performed at a temperature of 1000 ° C. or higher. The carbonization temperature range is preferably 1000 to 3000 ° C, more preferably 1000 to 2200 ° C. The carbonization treatment time is, for example, about 10 minutes to 1 hour. Moreover, the pretreatment by baking in an inert atmosphere of about 300 to 800 ° C. can be performed before the carbonization treatment.

  When carbonizing the continuously manufactured precursor sheet, it is preferable to perform the carbonizing process continuously over the entire length of the precursor sheet from the viewpoint of reducing the manufacturing cost. If the porous electrode base material is long, the handling property is high, the productivity of the porous electrode base material is high, and the subsequent production of the membrane-electrode assembly (MEA) can also be performed continuously. The manufacturing cost of the fuel cell can be reduced. Moreover, it is preferable to wind up the manufactured porous electrode base material continuously from a viewpoint of productivity and reduction of manufacturing cost of a porous electrode base material and a fuel cell.

Step (4): A step of impregnating a papermaking body with a thermosetting resin and drying / molding As described above, the present invention is a heat treatment in step (2), whereby carbon fiber precursor short fibers (b), fibrils are formed. Carbon-like precursor fibers (b′-1) and / or short carbon fibers (A) of a thermosetting resin are promoted, and short carbon fibers (A) formed by molding in step (4) to be described later The surface structure of the carbon fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b′-1) and / or the thermosetting resin described later is not only strengthened. Reform. The carbon fiber precursor short fiber (b) and / or the fibrillated carbon precursor fiber (b′-1) and / or the modified surface of the thermosetting resin described later is the carbon fiber precursor short fiber (b). And / or fibrillar carbon precursor fiber (b′-1) and / or the entire thermosetting resin described later, and serves as a protective film during carbonization, so that the carbon fiber precursor Short body fibers (b) and / or fibrillar carbon precursor fibers (b'-1) and / or the weight loss inside the thermosetting resin described later can be prevented, and the carbonization yield can be greatly improved. . Therefore, the paper body to be heat-treated in the step (2) always includes at least one of the fiber precursor short fiber (b), the fibrillar carbon precursor fiber (b′-1), and the thermosetting resin. Need to be. Therefore, when the papermaking body obtained in the step (1) does not contain any of the fiber precursor short fibers (b) and the fibrillar carbon precursor fibers (b′-1), the step is performed before the step (2). (4) must be provided to impregnate the papermaking body with a thermosetting resin. That is, step (4) must be provided between step (1) and step (2).

  In addition, carbon short fibers (A) are strongly bonded to each other with carbonaceous matter by carbon fiber precursor short fibers (b), fibrillar carbon precursor fibers (b′-1) and / or carbides of thermosetting resin. From the viewpoint of improving the apparent bulk density of the porous electrode substrate to improve the strength, and forming a porous electrode substrate with high electrical conductivity by forming a large number of conductive paths. Even if the papermaking body obtained in the step (1) contains either the carbon fiber precursor short fiber (b) or the fibrillar carbon precursor fiber (b′-1), the step (1 ) And step (2) are preferably provided with step (4).

<Thermosetting resin>
As the thermosetting resin to be impregnated into the papermaking body, a known resin that can bind the carbon fiber of the gas diffusion layer at the stage of carbonization can be appropriately selected and used. From the viewpoint of easily remaining as a conductive substance after carbonization, a phenol resin, an epoxy resin, a furan resin, pitch, and the like are preferable, and a phenol resin having a high carbonization rate is particularly preferable when carbonized by heating.

<Impregnation method>
As a method for impregnating the thermosetting resin, a known method can be used. For example, a dip method, a kiss coat method, a spray method, a curtain coat method, or the like can be used. In particular, from the viewpoint of production cost, it is preferable to use a spray method or a curtain coat method.

<Drying and molding process>
A known technique can be used as a drying method. For example, a drum drying method in which a heated roll is brought into contact with the heated roll or a drying method using hot air can be used. From the standpoint of maintenance, drying by a non-contact method is preferable. The drying temperature is preferably 60 to 110 ° C., more preferably 70 to 100 ° C., at which the resin does not cure.

  The process of molding the paper body after resin impregnation and drying is important. As a result, the short carbon fibers (A) in the precursor sheet are fused with the short carbon fiber precursor fibers (b) and / or the fibrillar carbon precursor fibers (b′-1), and the thermosetting resin is cured. By doing so, a strong conductive path of the porous carbon electrode substrate after carbonization is formed. By causing the carbon fiber precursor short fiber (b), the fibrillar carbon precursor fiber (b′-1) and / or the thermosetting resin to be fused to the carbon short fiber (A) in the molding process, In the subsequent heat treatment step, the fusion proceeds further, and the carbonization yield of the carbon fiber precursor short fiber (b), the fibrillar carbon precursor fiber (b′-1) and / or the thermosetting resin is improved.

  Any technique can be applied as long as the papermaking body can be uniformly heated and pressed. For example, a method in which a smooth rigid plate is applied to both sides of the paper body and hot-pressed, a continuous roll press apparatus, and a continuous belt press apparatus are used.

In the case where the continuously produced paper body is heated and pressed, a method using a continuous roll press device or a continuous belt press device is preferable. Thereby, the subsequent heat treatment and carbonization treatment can be performed continuously. Examples of the pressing method in the continuous belt press apparatus include a method of applying pressure to the belt with a linear pressure by a roll press, a method of pressing with a surface pressure by a hydraulic head press, and the like. The latter is preferred in that a smoother porous electrode substrate can be obtained.
In order to effectively smooth the surface of the precursor sheet, the heating temperature in the hot pressing is preferably less than 200 ° C, more preferably 120 to 190 ° C.

  Although the molding pressure is not particularly limited, when the content ratio of the carbon fiber precursor short fibers (b) and / or the fibrillar fibers (b ′) in the papermaking body is large, the sheet Y can be easily formed even if the molding pressure is low. The surface can be smoothed. If the press pressure is increased more than necessary at this time, there may be a problem that the short carbon fibers (A) are destroyed at the time of heat and pressure molding, a problem that the structure of the porous electrode substrate becomes too dense, or the like. is there. The molding pressure is preferably about 20 kPa to 10 MPa.

  The time for heat and pressure molding can be, for example, 30 seconds to 10 minutes. When the paper body is sandwiched between two rigid plates or heated and pressed with a continuous roll press or continuous belt press, carbon fiber precursor short fibers (b) and / or fibrils are applied to the rigid plate or roll or belt. It is preferable to apply a release agent in advance so that the carbon-like carbon precursor fibers (b ′) do not adhere, or to sandwich the release paper between the papermaking body and the rigid plate or roll or belt.

Step (5): Step of entangling the paper body The sheet-like material is entangled to obtain 3 carbon short fibers (A), carbon fiber precursor short fibers (b) and / or fibril fibers (b '). A sheet having an entangled structure entangled in a dimension (entangled structure sheet) can be formed.

  The entanglement process can be selected as needed from the method of forming the entangled structure, and is not particularly limited. A mechanical entanglement method such as a needle punching method, a high pressure liquid injection method such as a water jet punching method, a high pressure gas injection method such as a steam jet punching method, or a combination thereof can be used. It is possible to easily suppress the breakage of the short carbon fibers (A) and the breakage of the carbon fiber precursor short fibers (b) and / or the fibrillar fibers (b ′) in the entanglement treatment step, and appropriate entanglement The high-pressure liquid injection method is preferable in that the property can be easily obtained. Hereinafter, this method will be described in detail.

  The high-pressure liquid jet treatment is a paper-making process in which a paper-making body is placed on a substantially smooth support member and a liquid columnar flow, a liquid fan-shaped flow, a liquid slit flow, or the like is ejected at a pressure of 1 MPa or more. This is a treatment method in which the short carbon fibers (A) in the body are entangled with the short carbon fiber precursor fibers (b) and / or the fibrillar fibers (b ′). Here, the support member having a substantially smooth surface is selected as necessary from the one in which the pattern of the support member is not formed on the resulting entangled structure and the ejected liquid is quickly removed. Can be used. Specific examples thereof include a 30-200 mesh wire net, a plastic net, or a roll.

  From the viewpoint of productivity, it is preferable to continuously perform a confounding process such as a high-pressure liquid injection process after a paper body is manufactured on a substantially smooth support member.

  The entanglement process by high-pressure liquid injection of the paper body may be repeated a plurality of times. That is, after performing the high pressure liquid jet treatment of the paper body, the paper bodies may be further laminated and the high pressure liquid jet treatment may be performed, or the paper body having an entangled structure is turned over and the high pressure liquid jet process is performed from the opposite side. Liquid ejection processing may be performed. These operations may be repeated.

  The liquid used for the high-pressure liquid jet treatment is not particularly limited as long as it is a solvent that does not dissolve the fiber to be treated, but it is usually preferable to use water. The water may be warm water. In the case of a columnar flow, each jet nozzle hole diameter in the high-pressure liquid jet nozzle is preferably 0.06 to 1.0 mm, and more preferably 0.1 to 0.3 mm. The distance between the nozzle injection hole and the laminate is preferably 0.5 to 5 cm. The pressure of the liquid is preferably 1 MPa or more from the viewpoint of fiber entanglement, more preferably 1.5 MPa or more, and the entanglement treatment may be performed in one or more rows. When performing multiple rows, it is effective to increase the pressure in the second and subsequent high-pressure liquid ejection processes from the first row from the viewpoint of maintaining the paper body form.

  When a sheet (paper body) is continuously manufactured, a streak-like locus pattern is formed in the sheeting direction, and a dense structure may occur in the sheet (paper body). However, the locus pattern can be suppressed by oscillating a high-pressure liquid jet nozzle having one or more rows of nozzle holes in the width direction of the sheet (paper body). By suppressing the streaky locus pattern in the sheet forming direction, the tensile strength can be expressed in the sheet (paper body) width direction. When using a plurality of high-pressure liquid jet nozzles having one or a plurality of rows of nozzle holes, by controlling the frequency and phase difference of the high-pressure liquid jet nozzles that vibrate in the width direction of the sheet (paper body). The periodic pattern appearing on the entangled sheet (paper body) can also be suppressed.

  Since the tensile strength of the papermaking body is improved by the entanglement treatment step, it is not necessary to use a binder such as polyvinyl alcohol usually used in papermaking, and the tensile strength of the sheet can be maintained even in water or in a wet state.

  The step (5) may be provided between the step (1) and the step (2), and when the step (4) is included, it may be provided between the steps (1) and (4).

Various physical property values were measured using the following methods.

(Measurement of basis weight and bulk density)
From the 1 m width of the gas diffusion layer, 10 3 × 3 cm square test pieces were evenly taken out in the width direction, each thickness was measured with a micrometer, and the bulk density was calculated by weighing the weight with a balance. . The average value of the basis weight measured at 10 points was adopted as the representative value of the sample.
(Measurement of penetration direction resistance)
The electrical resistance (through-direction resistance) in the thickness direction of the porous electrode substrate is obtained by sandwiching the porous electrode substrate between gold-plated copper plates, pressurizing at 1 MPa from the top and bottom of the copper plate, and applying a current at a current density of 10 mA / cm ^2. The resistance value when flowing was measured and calculated from the following equation.

Through-direction resistance (mΩ · cm ² ) = Measured resistance value (mΩ) × Sample area (cm ² )
<Example 1>
As the carbon short fiber (A), a PAN-based carbon fiber having an average fiber diameter of 7 μm and an average fiber length of 3 mm was prepared. Further, as carbon fiber precursor short fibers (b), acrylic short fibers (Mitsubishi Rayon Co., Ltd., trade name: D122) having an average fiber diameter of 4 μm and an average fiber length of 3 mm, and fibrillar fibers (b ′) , An easily split fiber acrylic sea-island composite short fiber (made by Mitsubishi Rayon Co., Ltd., trade name: Bonnell MVP-C651, made of an acrylic polymer fibrillated by beating and diacetate (cellulose acetate), Average fiber length: 3 mm) was prepared.

A porous carbon electrode substrate was produced by the following operations (1) to (7).
(1) Disaggregation of carbon short fibers (A) The carbon short fibers (A) are dispersed in water so that the fiber concentration is 1% (10 g / L), disaggregated through a mixer, and disaggregated slurry fibers (SA) ).
(2) Disaggregation of carbon fiber precursor short fibers (b) The carbon fiber precursor short fibers (b) are dispersed in water so that the fiber concentration is 1% (10 g / L), and disaggregated through a mixer. A disaggregated slurry fiber (Sb) was obtained.
(3) Disaggregation of fibrillar fibers (b ′) The above split fiber acrylic sea-island composite short fibers are dispersed in water so that the fiber concentration is 1% (10 g / L) and beaten and disaggregated through a mixer. A disaggregated slurry fiber (Sb ′) was obtained.
(4) Production of paper body Carbon short fiber (A), carbon fiber precursor short fiber (b), and fibrillar fiber (b ') are in a mass ratio of 70:10:20, and the concentration of fibers in the slurry. However, the disaggregation slurry fiber (SA), the disaggregation slurry fiber (Sb), the disaggregation slurry fiber (Sb ′), and the dilution water were weighed and dispersed so as to be 1.44 g / L. For papermaking, a sheet drive unit consisting of a net drive unit and a flat net mesh made of plastic net with a width of 60cm x length of 585cm connected in a belt shape and continuously rotated, the slurry supply unit width is 48cm, the bottom of the net A processing apparatus consisting of a vacuum dehydration apparatus arranged in the above was used. A pressurized water jet treatment apparatus provided with the following three water jet nozzles was disposed downstream of the treatment apparatus.

Nozzle 1: hole diameter φ0.15 mm × 501 holes, width direction hole pitch 1 mm (1001 holes / width 1 m), single row arrangement, nozzle effective width 500 mm
Nozzle 2: hole diameter φ0.15 mm × 501 holes, pitch in the width direction hole 1 mm (1001 holes / width 1 m), one line arrangement, nozzle effective width 500 mm
Nozzle 3: hole diameter φ0.15 mm × 1002 holes, width direction hole pitch 1.5 mm, three rows, row pitch 5 mm, nozzle effective width 500 mm
The pressurized water jet pressure is 1MPa nozzle 1, pressure 2MPa (nozzle 2), pressure 1MPa (nozzle 3), and the slurry in which the fibers are dispersed is introduced from the slurry supply unit, and after dehydration under reduced pressure, nozzle 1, nozzle 2, nozzle The papermaking body having a three-dimensional entanglement structure was obtained by passing through in the order of 3 and applying entanglement treatment. The paper body was dried at 150 ° C. for 3 minutes by a pin tenter tester (PT-2A-400 manufactured by Sakurai Dyeing Machine Co., Ltd.) to obtain a paper body having a basis weight of 60 g / m ² . In addition, the dispersion state of the carbon short fiber (A), the carbon fiber precursor short fiber (b), and the fibrillar fiber (b ′) in the papermaking body was good, and the handling property was also good.
(5) Pressurization and heating molding Next, both sides of this papermaking body are arranged so as to be sandwiched by paper coated with a silicone release agent, and at 190 ° C. and a belt speed of 0.2 m / min with a double belt press device. The press molding was performed.
(6) A heat treatment furnace (manufactured by NGK Kiln Tech Co., Ltd.) having a heating length of 1 m in which far infrared heaters are arranged on the upper and lower surfaces was used for the heat treatment step of the heat treatment molded sheet. The temperature of the heat treatment furnace was set to 300 ° C., and the cut molded sheet was fed at a speed of 0.2 m / min to obtain a precursor sheet. The execution heat treatment time was 12 seconds. The precursor sheet after the heat treatment was discolored from yellow to brown.
(7) Carbonization treatment Thereafter, this precursor sheet was carbonized in a batch carbonization furnace in a nitrogen gas atmosphere at 2000 ° C. for 1 hour to obtain a porous carbon electrode substrate. The carbonization yield of the obtained porous carbon electrode substrate was as high as 65.14%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 2>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the conveyance speed was 1 m / min when the heat treatment was performed. The carbonization yield of the obtained porous carbon electrode substrate was as high as 61.27%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 3>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the conveyance speed was 5 m / min when the heat treatment was performed. The carbonization yield of the obtained porous carbon electrode substrate was as high as 51.71%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 4>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 330 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 67.42%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 5>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that the heat treatment temperature was 330 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 62.70%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 6>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature was 330 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 54.37%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 7>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 360 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 68.53%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 8>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that the heat treatment temperature during the heat treatment was 360 ° C. The carbonization yield of the obtained porous carbon electrode substrate was as high as 66.15%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 9>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature during the heat treatment was 360 ° C. The carbonization yield of the obtained porous carbon electrode substrate was as high as 56.94%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 10>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 390 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 72.49%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 11>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that the heat treatment temperature was 390 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 67.70%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 12>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature was 390 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 56.51%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 13>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 420 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 70.71%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 14>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that the heat treatment temperature was 420 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 70.82%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 15>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature was 420 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 59.67%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 16>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 450 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 56.19%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 17>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that the heat treatment temperature was 450 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 69.15%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 18>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature was 450 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 60.08%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 19>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that wood pulp that is generally commercially available was used as the fibrillar fiber (b ′) and beaten with a pulper. The carbonization yield of the obtained porous carbon electrode substrate was as high as 61.75%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 20>
A porous carbon electrode substrate was produced in the same manner as in Example 2 except that wood pulp was used as the fibrillar fiber (b ′) and beaten with a pulper. The carbonization yield of the obtained porous carbon electrode substrate was as high as 55.41%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Example 21>
A porous carbon electrode substrate was produced in the same manner as in Example 3 except that the heat treatment temperature was 450 ° C. when performing the heat treatment. The carbonization yield of the obtained porous carbon electrode substrate was as high as 50.09%, and the penetration direction resistance was also good. The evaluation results are shown in Table 1.
<Comparative Example 1>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment was not performed. The carbonization yield of the obtained porous carbon electrode substrate was as low as 44.32%. Further, the penetration direction resistance was a common value of 10.45 mΩ · cm 2. The evaluation results are shown in Table 1.
<Comparative example 2>
A porous carbon electrode substrate was produced in the same manner as in Example 19 except that no heat treatment was performed. The carbonization yield of the obtained porous carbon electrode substrate was as low as 40.21%. Further, the penetration direction resistance was a common value of 11.55 mΩ · cm 2. The evaluation results are shown in Table 1.
<Comparative Example 3>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the conveyance speed was reduced to 0.005 m / min (5 mm / min) during the heat treatment. Since the oxidation treatment was excessively performed in the heat treatment process, the carbonization yield of the obtained porous carbon electrode substrate was as low as 40.51%, and the penetration direction resistance was 11.21 mΩ · cm 2 as a general value. Met. The evaluation results are shown in Table 1.
<Comparative example 4>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the conveyance speed was increased to 10 m / min when the heat treatment was performed. Since the oxidation treatment was insufficient in the heat treatment step, the carbonization yield of the obtained porous carbon electrode substrate was as low as 45.33% and the penetration resistance was generally 10.55 mΩ · cm 2. Value. The evaluation results are shown in Table 1.
<Comparative Example 5>
When the heat treatment was performed, the same procedure as in Example 1 was performed except that the heat treatment temperature was 450 ° C. and the conveyance speed was 0.005 m / min (5 mm / min). However, the sheet was remarkably deformed and damaged in the heat treatment step, the sheet form could not be maintained, and a porous carbon electrode substrate could not be obtained. Therefore, the carbonization yield and penetration direction resistance could not be measured.
<Comparative Example 6>
A porous carbon electrode substrate was produced in the same manner as in Example 1 except that the heat treatment temperature was 450 ° C. and the conveyance speed was 10 m / min. Since the oxidation treatment was insufficient in the heat treatment step, the carbonization yield of the obtained porous carbon electrode substrate was as low as 46.43% and the penetration resistance was generally 10.11 mΩ · cm 2. Value. The evaluation results are shown in Table 1.

Claims (6)

The manufacturing method of the porous carbonaceous electrode base material including the following processes.
Step (1): A step of producing a paper body in which short carbon fibers (A), carbon fiber precursor short fibers (b) and / or fibrillar fibers (b ′) are dispersed.
Step (2): A step of subjecting the paper body to a heat treatment at 300 to 450 ° C. for 10 to 300 seconds in an oxygen atmosphere to obtain a porous electrode substrate precursor sheet.
Step (3): A step of producing a porous carbonaceous electrode substrate by carbonizing the precursor sheet obtained in the step (2) at 2000 to 3000 ° C. in a nitrogen atmosphere.
When the papermaking body in the step (1) does not include the fiber precursor short fiber (b) and / or the fibrillar carbon precursor fiber (b′-1), between the step (1) and the step (2), There is a step (4) of impregnating the papermaking body with a thermosetting resin, followed by drying and molding.   The manufacturing method of Claim 1 which has the process (4) which impregnates a papermaking body with a thermosetting resin between a process (1) and process (2), and then performs drying and shaping | molding.   In the case where the step (4) is included between the step (1) and the step (2), the step (5) for confounding the paper body is included between the steps (1) and (4). The manufacturing method as described.   The manufacturing method according to claim 2, further comprising a step (5) of tangling the paper body between the step (1) and the step (4).   The manufacturing method according to claim 1, wherein the heat treatment method in the step (3) is heating by far infrared rays.   The manufacturing method according to any one of claims 1 to 4, wherein the heat treatment method in the step (3) is contact-type heating using an induction heating roll.