JP2013518365A - プロトン伝導性膜を製造する方法 - Google Patents
プロトン伝導性膜を製造する方法 Download PDFInfo
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Classifications
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Abstract
Description
1.すべての液体物質及びすべての固形分を別々にプレブレンドする工程;
2.別の速度及び温度で数時間撹拌しながら、溶媒中に固形分を分散させる工程;及び
3.得られた溶液は、ここでキャスティング準備が整い、数週間密閉容器に保存できる。
好ましい固体電解質膜は、30nmより本質的に小さい直径サイズを有する孔を有するプロトン伝導性膜であり、(i)良好な酸吸収容量を有する電気的に非伝導性の無機粉末5体積%〜60体積%であって、本質的にナノサイズの粒子を含む粉末;(ii)酸、酸素及び前記燃料と化学的に適合性のポリマーバインダ5体積%〜50体積%;及び(iii)酸又は酸水溶液10〜90体積%を含む。
200グラムのPVDF及び400m2/gの面積を有する105.6gの二酸化ケイ素(「シリカ」)を混合する。異なるフラスコにおいて、処理溶媒(241.6グラムのDBP及び1320グラムのDMF)及びレオロジー制御剤(10グラムのSPAN80及び0.6グラムのZonil)を混合する。粉末を低混合割合(200rpm)にて室温で溶媒中に3時間分散させる。混合割合を500rpmまで上昇させながら、40℃で16時間加熱する。室温で300rpmにてさらに16時間脱気のために撹拌し(混合物中に捕捉された空気を除去)、続いて35℃で混合することなく、制御された温度環境に6時間おく。次いで溶液を、NIR−LNR−0063R−01タイプのシリコン処理された紙が充填されたコーティング機(http://www.dixontechnologies.com/marketspilot.htmlに記載されるDixon Model 160 Mk2)に移す。ナイフギャップは、180マイクロメートルに設定し、回転速度を毎分0.5メートルにした。
・エーテル:エタノール浴は、こうした溶媒を1:9の比で含有し、膜は、孔のDBPを抽出するために2時間浴に含浸される;
・DBPの残り及び他の潜在溶媒を除去するために2時間にわたってエタノール浴に含浸させ;及び
・水浴(脱イオン水)−孔からエタノールを除去するために含浸される。
混合及びキャスティング手順は、材料の量が次の式に従って変更されている以外、実施例1に記載される手順と同一である。
(数1)284.8グラムのPVDF、88グラムのシリカ、311.8グラムのDBP、12.5グラムのSPAN80、1377.4グラムのDMF、0.2グラムのZonil
3Mの硫酸で1時間沸騰させた後、室温での伝導率について実施例1及び2の膜をSolartron 1260を用いて試験した。伝導率は、実施例1及び2についてそれぞれ0.144S/cm−1及び0.102S/cm−1であった。それは良好な酸吸収性を有するので伝導性は充分である。以下の表1は、ここで使用されている最新の自動化プロセスに対して、以前の手動小規模プロセスにて製造されるいくつかの膜の伝導率を示す。全体として、大規模プロセスは、0.1〜0.2S/cm−1の許容可能な範囲内で膜の伝導率特性を保持する。
ii−Electrochemical and Solid−State Letters,3(12)(2000)
iii−Journal of Power Sources 161(2006)1187−1191
iv−Electrochemical and Solid−State Letters,7(12)(2004)507
v−Electrochemical and Solid−State Letters,6(12)A268−A271(2003)
以下の表2は、本開示のプロトン伝導性膜を製造するプロセスと従来のプロセス工程における相違を要約した。
大部分の改善により、時間と労力が節約される、すなわち得られたフィルムの良好な質を伴う効率の良いプロセスである。プロセスの再現性は、信頼でき、簡便である;フィルムは均質でより強靭であり、表1に示されるように、許容できる範囲内及び統計学的エラーの範囲内において、膜の物理的特性に微量の無視できる程度の影響を与えるだけである。
Claims (26)
- プロトン伝導性膜を製造するためのプロセスであって、前記プロセスが:
(i)良好な酸吸収容量を有する電気的に非伝導性の無機粉末5体積%〜60体積%であって、前記粉末が本質的にナノサイズ粒子を含む粉末;(ii)酸、酸化剤及び燃料と化学的に適合性であるポリマーバインダ5体積%〜50体積%;及び(iii)酸又は酸水溶液10〜90体積%を混合する工程であって、ここで前記混合が種々の割合の工程にて行われることによって混合物を生じる工程;
前記混合物をロール紙、不織布マトリックス上に周囲温度にて連続的にキャスティングを行う工程;
前記キャスティングされた混合物を100℃を超える温度で乾燥させることによって、乾燥フィルムを形成する工程;及び
複数の前記乾燥フィルムを共に圧力下で積層させ、その後前記乾燥フィルムの孔から孔形成剤を抽出することによって、30ナノメートル未満の平均孔サイズを有するプロトン伝導性膜を形成する工程
を含む、プロセス。 - 少なくとも4つの前記乾燥フィルムを共に積層させる、請求項1に記載のプロセス。
- 前記混合工程の前記種々の割合の工程が、
約100〜500rpmの混合割合にて室温で1〜5時間混合する工程;
約400〜700rpmの混合割合にて約30〜50℃の範囲の温度で10〜20時間混合する工程;
約100〜400rpmの混合割合にて室温で10〜20時間混合する工程;及び
約30〜50℃の範囲の温度にて5〜30時間脱気する工程
を含む、請求項1に記載のプロセス。 - 前記乾燥フィルムが、約40〜60マイクロメートルの厚さを有する、請求項1に記載のプロセス。
- 前記乾燥フィルムが、約50〜55マイクロメートルの厚さを有する、請求項4に記載のプロセス。
- 前記乾燥フィルムの前記積層工程が、約5〜20kg/cm2の範囲の圧力下、約140〜145℃の範囲の温度にて約3〜10分間行われる、請求項1に記載のプロセス。
- 前記プロトン伝導性膜が、3nm未満の平均孔サイズを有する、請求項1に記載のプロセス。
- 前記プロトン伝導性膜が、1.5nm未満の平均孔サイズを有する、請求項7に記載のプロセス。
- 前記乾燥工程が、約5〜60分間行われる、請求項1に記載のプロセス。
- 前記プロトン伝導性膜が実質的にクラックを含まない、請求項1に記載のプロセス。
- 少なくとも1つのレオロジー制御剤が混合前に添加される工程をさらに含む、請求項1に記載のプロセス。
- 前記抽出工程が:
(a)前記プロトン伝導性膜の孔から前記孔形成剤を除去するのに十分な期間、エーテル/エタノール混合物中、孔形成剤を有するプロトン伝導性膜を含浸する工程;
(b)残存する孔形成剤及び他の溶媒を除去するために工程(a)からの前記プロトン伝導性膜をエタノール中に含浸する工程;及び
(c)前記孔から前記エタノールを除去するために水中に前記プロトン伝導性膜を含浸する工程
を含む、請求項1に記載のプロセス。 - 前記エーテル/エタノール混合物が、約1:9〜3:7の比を有する、請求項12に記載のプロセス。
- 前記含浸工程(a)が、約1〜5時間行われる、請求項12に記載のプロセス。
- 前記含浸工程(b)が、約1〜5時間行われる、請求項12に記載のプロセス。
- 前記無機粉末が、SiO2、ZrO2、B2O3、TiO2、Al2O3、ならびにTi、Al、B及びZrの水酸化物及びオキシ水酸化物からなる群から選択される少なくとも1つの粉末である、請求項1に記載のプロセス。
- 前記ポリマーバインダが、ポリ(ビニリデンフルオリド)、ポリ(ビニリデンフルオリド)ヘキサフルオロプロピレン、ポリ(テトラフルオロエチレン)、ポリ(メチルメタクリレート)、ポリ(スルホンアミド)、ポリ(アクリルアミド)、ポリ(ビニルクロリド)、アクリロニトリル、ポリ(ビニルフルオリド)、及びクロロトリフルオロエチレンのホモポリマーからなる群から選択される少なくとも1つのバインダである、請求項1に記載のプロセス。
- 前記酸が、ポリフルオロオレフィンスルホン酸、ペルフルオロオレフィンスルホン酸、ポリフルオロアリールスルホン酸、ペルフルオロアリールスルホン酸、(ここで水素又はフッ素原子の50%までが、塩素原子によって置き換えられている)、CF3(CF2)nSO3H、HO3S(CF2CH2)nSO3H、CF23(CF2CH2)nSO3H、HO3S(CF2)nSO3H、ここでnは1から9の値を有する整数である、ペルフルオロスルホン酸コポリマー、HCl、HBr、リン酸及び硫酸からなる群から選択される少なくとも1つである、請求項1に記載のプロセス。
- 前記ポリフルオロアリールスルホン酸が、ポリフルオロベンゼン、ポリフルオロトルエン、及びポリフルオロスチレンスルホン酸からなる群から選択される少なくとも1つである、請求項18に記載のプロセス。
- 前記ペルフルオロアリールスルホン酸が、ペルフルオロベンゼン、ペルフルオロトルエン及びペルフルオロスチレンスルホン酸からなる群から選択される少なくとも1つである、請求項18に記載のプロセス。
- ジブチルフタレート、ジエチルフタレート、ジメチルフタレート、プロピレンカーボネート、及びエチレンカーボネートからなる群から選択される少なくとも1つの孔形成剤をさらに含む、請求項1に記載のプロセス。
- 前記レオロジー制御剤は:ソルビタンモノオレエート、C24H44O6、及び非イオン性フルオロ界面活性剤(C2H4O)x(CF2)yC2H5FOからなる群から選択される少なくとも1つである、請求項11に記載のプロセス。
- 前記酸又は酸水溶液を再捕捉する工程をさらに含む、請求項1に記載のプロセス。
- 前記プロトン伝導性混合物を連続的にキャスティングする前記工程が、ロール紙、不織布マトリックスなど、ロール・ツー・ロールキャリア支持体にわたって溶液適用するためのコーター機を用いて行われる、請求項1に記載のプロセス。
- 前記キャリア支持体が、シリコン処理された紙であり、前記キャリア支持体の回転速度が、前記プロトン伝導性混合物の比重に従って設定される、請求項24に記載のプロセス。
- 請求項1のプロセスによって形成されるプロトン伝導性膜。
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JP2002505506A (ja) * | 1998-02-24 | 2002-02-19 | ラモツト・ユニバーシテイ・オーソリテイ・フオー・アプライド・リサーチ・アンド・インダストリアル・デベロツプメント・リミテツド | イオン伝導性マトリックスおよびそれの使用 |
JP2003520413A (ja) * | 2000-01-18 | 2003-07-02 | ラモツト・アット・テル−アビブ・ユニバーシテイ・リミテッド | 新規な燃料 |
JP2003520412A (ja) * | 2000-01-18 | 2003-07-02 | ラモツト・アット・テル−アビブ・ユニバーシテイ・リミテッド | プロトン伝導膜を有する燃料電池 |
JP2010010033A (ja) * | 2008-06-30 | 2010-01-14 | Toshiba Corp | プロトン伝導性膜、それを用いた膜電極複合体および燃料電池 |
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