JP2014148449A - Porous electrode substrate precursor sheet, method for producing the same, porous electrode substrate, membrane-electrode assembly, and solid polymer type fuel cell - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a porous electrode substrate precursor sheet which is low in production cost in producing a precursor sheet and reduced in fiber bundles in which carbon fibers are bundled, and to provide a method for producing the same.SOLUTION: There is provided a method for producing a porous electrode substrate precursor sheet by making paper from a fiber mixed slurry composed of a mixture containing carbon short fibers (A) and precursor fibers (b), in which the following (I) to (IV) are performed. (I) A dewaterable adjusting agent is mixed with a dispersion medium (A) to obtain dispersion medium (B) containing a dewaterable adjusting agent. (II) The dispersion medium (B) obtained in (I) and the carbon short fibers (A) are mixed to obtain a slurry (A). (III) The slurry (A) obtained in (II) and the precursor fibers (b) are mixed to obtain a slurry (B). (IV) The slurry (B) obtained in (II) is made into paper to obtain a porous electrode substrate precursor sheet composed of a fiber mixture of the carbon short fibers (A) and the precursor fibers (b).

Description

  The present invention relates to a precursor sheet for a porous electrode substrate used in a polymer electrolyte fuel cell, a method for producing the same, and a porous electrode substrate.

  A polymer electrolyte fuel cell is characterized by using a proton-conducting polymer electrolyte membrane, and is an apparatus for obtaining an electromotive force by electrochemically reacting a fuel gas such as hydrogen and an oxidizing gas such as oxygen. is there. In such a polymer electrolyte fuel cell, two sets of gas diffusion electrodes each having a catalyst layer mainly composed of carbon powder supporting a noble metal catalyst and a gas diffusion electrode substrate are arranged on the inner side of each catalyst layer. Thus, the polymer electrolyte membrane has a structure bonded to both surfaces.

  The gas diffusion electrode substrate is generally composed of a carbonaceous material, and the precursor sheet of the gas diffusion electrode substrate is composed of a carbonaceous material and a carbonaceous precursor material. It is manufactured by a wet papermaking method using carbonaceous fibers. When a fiber bundle of carbonaceous fibers is present, unevenness occurs in gas diffusibility when used as a gas diffusion electrode substrate. Therefore, in the precursor sheet manufacturing method by the wet papermaking method, carbonaceous fibers are dispersed. The concentration of the slurry is adjusted to about 0.05 to 0.5 g / L to form a sheet. As a general gas diffusion electrode substrate precursor sheet and gas diffusion electrode substrate, for example, the following gas diffusion electrode substrate precursor sheet and gas diffusion electrode substrate are known.

  Patent Document 1: A carbon fiber nonwoven fabric comprising 70% by mass or more of polyacrylonitrile-based carbon short fibers, wherein the carbon fibers are hydroentangled with each other.

Patent Document 2: The thickness is 0.05 to 0.5 mm and the bulk density is 0.3 to 0.8 g / cm ³ .
In a three-point bending test under the conditions of a strain rate of 10 mm / min, a distance between fulcrums of 2 cm, and a specimen width of 1 cm, the bending strength is 10 MPa or more and the bending deflection is 1.5 mm or more. A porous carbon electrode substrate for a fuel cell.

  Patent Document 3: A mat comprising a plurality of carbon fibers; and a plurality of acrylic pulp fibers incorporated into the carbon fiber mat, the acrylic pulp fibers being cured and carbonized after being incorporated into the carbon fiber mat. Gas diffusion layer for a fuel cell.

Patent Document 4: In a method for producing a carbon fiber sheet by firing a polyacrylonitrile-based oxidized fiber sheet, the bulk density is obtained by compressing the polyacrylonitrile-based oxidized fiber sheet in the thickness direction under conditions of 150 to 300 ° C. and 10 to 100 MPa. Of carbon fiber sheet, characterized by obtaining an oxidized fiber sheet subjected to a compression treatment of 0.40 to 0.80 g / cm ³ and a compression ratio of 40 to 75%, and then firing the oxidized fiber sheet subjected to the compression treatment Method.

  Patent Document 5: Step (I) of feeding a reinforcing fiber bundle into a dispersion medium, step (II) of preparing a slurry in which reinforcing fibers constituting the reinforcing fiber bundle are dispersed in the dispersion medium, and step of transporting the slurry (III) and a step (IV) of obtaining a papermaking substrate containing reinforcing fibers by removing the dispersion medium from the slurry, and having a mass content of reinforcing fibers in the slurry prepared in the step (II) C1 and when the mass content of reinforcing fibers in the slurry at the start of the step (IV) is C2, C1 / C2 of the papermaking substrate containing reinforcing fibers in the range of 0.8 to 1.2 Production method. And the manufacturing method of the papermaking base material whose mass content rate of the reinforced fiber in a slurry is 0.01-1 mass%.

  However, the carbon fiber nonwoven fabric disclosed in Patent Document 1 has a problem in handling due to low mechanical strength due to the entanglement of carbon fibers with high rigidity. The porous carbon electrode substrate disclosed in Patent Document 2 has high mechanical strength and surface smoothness and sufficient gas permeability and conductivity, but has a problem of high manufacturing cost. It was. The gas diffusion layer for fuel cells disclosed in Patent Document 3 can be manufactured at low cost, but there is little entanglement between carbon fiber and acrylic pulp when forming into a sheet, and handling is difficult was there. In addition, since acrylic pulp has almost no molecular orientation of the polymer compared to fibrous materials, the carbonization rate during carbonization is low, and it was necessary to add a large amount of acrylic pulp in order to improve handling properties. . The carbon fiber sheet and the carbon fiber non-woven fabric disclosed in Patent Document 4 can be manufactured at low cost, but the shrinkage during firing is large, the thickness unevenness of the obtained sheet or the like is large, and the sheet waviness ( There is a problem that the sheet cross-section is wavy or warped.

  In addition, when the precursor sheet of the gas diffusion electrode substrate and the gas diffusion electrode substrate are manufactured by a wet papermaking method, it is necessary to use a low-concentration slurry in order to reduce the fiber bundle in which the carbon fibers are concentrated. In addition, a large utility for dehydrating the water is required, which increases the production cost of the precursor sheet.

  Although the papermaking substrate manufacturing method disclosed in Patent Document 5 controls the dilution in each step of the papermaking slurry, the carbon fiber when the concentration of fibers containing carbon fibers in the papermaking slurry is increased No method has been proposed to reduce the bundle of bundles of fibers, and as a papermaking substrate used as a gas diffusion electrode substrate for a fuel cell, many bundles of carbon fibers are produced under conditions of high concentration slurry. There was a problem to do.

JP 2002-266217 A International Publication No. 2001/056103 Pamphlet JP 2007-273466 A International Publication No. 2002/042534 Pamphlet JP 2010-37666 A

  The present invention overcomes the problems as described above, has a low production cost when producing a precursor sheet, and has a small number of fiber bundles in which short carbon fibers are concentrated, and a porous electrode substrate precursor sheet thereof A porous electrode base material having excellent handling properties and surface smoothness when used as a manufacturing method and a porous electrode base material, improved sheet thickness unevenness and undulation, and sufficient gas permeability and conductivity It aims at providing the manufacturing method.

  As a result of intensive investigations to solve the above problems, the present inventors have optimized the mixing conditions of the dehydrating modifier, the short carbon fiber (A), and the precursor fiber (b), so that the short carbon fiber and the precursor can be obtained. It has been found that the body fibers can be uniformly dispersed in the dispersion medium, and the fiber bundles in which the short carbon fibers and the precursor fibers are converged can be reduced, thereby completing the present invention. That is, the gist of the present invention resides in the following [1] to [17].

  [1] In a method for producing a porous electrode substrate precursor sheet by paper-making a fiber mixed slurry comprising a mixture containing carbon short fibers (A) and precursor fibers (b), the following (I) to (IV) ). A method for producing a porous electrode base material precursor sheet.

  (I) A dehydrating modifier is mixed with the dispersion medium (A) to obtain a dispersing medium (B) containing the dehydrating modifier.

  (II) The dispersion medium (B) obtained in the above (I) and the short carbon fiber (A) are mixed to obtain a slurry (A).

  (III) The slurry (A) obtained in (II) and the precursor fiber (b) are mixed to obtain a slurry (B).

  (IV) (IV) Porous made of a fiber mixture of short carbon fibers (A) and precursor fibers (b) by making the slurry (B) obtained in (III) as a papermaking slurry (C) An electrode substrate precursor sheet is obtained.

  In the above (I) to (IV), the following conditions are satisfied.

  In the above (I), the amount of the dehydrating regulator is 0.01 to 0.1 g / L per 1 L of the papermaking slurry (C) dispersion medium.

  In said (II), the quantity of a short carbon fiber (A) is an quantity used as 1-10g per 1L of dispersion media of a slurry (A).

  In the above (III), the amount of the precursor fiber (b) is an amount satisfying the following formula 1 by mass ratio.

(Formula 1)
0.1 ≦ precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A)) ≦ 0.6
[2] In the mixing of the slurry (A) and the precursor fiber (b) in (III), the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating regulator are mixed to form a slurry ( The production method according to [1], wherein the slurry (D) is mixed with the slurry (A) obtained in (II).

  [3] The production method according to claim 2, wherein after the slurry (D) is obtained, a dehydrating regulator is added to the slurry (D) and then mixed with the slurry (A) obtained in (II).

  [4] To the slurry (D), a dehydrating modifier diluted with the dispersion medium (A-2) is added, and then mixed with the slurry (A) obtained in (II) to obtain 0.8 per liter of the dispersion medium. A slurry (B-1) mixed with ˜1.8 g of fiber material is obtained, and the slurry (B-1) is changed to the slurry (B) in the above (IV), and paper is made as the papermaking slurry (C) [2 ] The manufacturing method of description.

  [5] The mixing of the slurry (A) and the precursor fiber (b) in the above (III) is performed by mixing the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating regulator (Slurry ( D) and the slurry (D) is mixed with the slurry (A) obtained in (II) and the dispersion medium (A-3), and 0.8 to 1.8 g of fiber material is mixed per liter of the dispersion medium. The slurry (B-1) is obtained, and the slurry (B-1) is changed to the slurry (B) in (IV), and the slurry (B-1) is made as the papermaking slurry (C).

  [6] After obtaining the slurry (D), a dehydrating regulator is added to the slurry (D), and then mixed with the slurry (A) obtained in (II) and the dispersion medium (A-3) [ [5].

  [7] Slurry (B-1) in which the slurry (B) is diluted with the dispersion medium (A-3) and 0.8 to 1.8 g of fiber material is mixed per liter of the dispersion medium in (III) The manufacturing method according to any one of [1] to [3], wherein in (IV), the slurry (B-1) is changed to the slurry (B) and paper is made as the papermaking slurry (C).

  [8] The mixing of the slurry (A) and the precursor fiber (b) in the above (III) is performed by mixing the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating regulator (Slurry ( D-1), the slurry (D-1) is mixed with the slurry (A) obtained in (II), and a slurry (0.8 to 1.8 g fiber material per 1 L of dispersion medium) is mixed ( B-1) is obtained, and the slurry (B-1) is changed to the slurry (B) in (IV), and the slurry (B-1) is made as papermaking slurry (C).

  [9] After obtaining the slurry (D-1), add a dehydrating regulator to the slurry (D-1), and then mix with the slurry (A) obtained in (II). Manufacturing method.

  [10] The porous electrode substrate precursor sheet obtained in any one of [1] to [9] above is heated and pressurized, and the heated and pressurized porous electrode substrate precursor sheet is heated to a temperature of 1000 ° C. or higher. A method for producing a porous electrode base material, which is carbonized in the process.

  [11] The production method according to [10], wherein the heated and pressurized porous electrode substrate precursor sheet is oxidized between the heat and pressure treatment and the carbonization treatment.

  [12] Either of the above [10] or [11], wherein the porous electrode substrate precursor sheet obtained by the production method described in [1] to [9] is entangled before the heat and pressure treatment The manufacturing method as described in.

  [13] The production method according to any one of [10] or [11], wherein the porous electrode substrate precursor sheet is impregnated with the carbonizable resin (c) before the heat and pressure treatment.

  [14] The production method according to [12], wherein the porous electrode substrate precursor sheet is impregnated with the carbonizable resin (c) between the entanglement treatment and the heat and pressure treatment.

  [15] A porous electrode substrate obtained by the method according to any one of [10] to [14].

  [16] A membrane-electrode assembly using the porous electrode substrate according to [15].

  [17] A polymer electrolyte fuel cell using the membrane-electrode assembly according to [16].

  According to the present invention, the porous electrode base material precursor sheet, the manufacturing cost thereof, and the porous electrode base material are low in manufacturing cost when the precursor sheet is manufactured and the number of fiber bundles in which carbon fibers are bundled is small. It is possible to provide a porous electrode substrate having excellent handling properties and surface smoothness, improved sheet thickness unevenness and undulation, and sufficient gas permeability and conductivity, and a method for producing the same. .

It is a figure which shows an example of implementation of said [1]. It is a figure which shows an example of implementation of said [2]. It is a figure which shows an example of implementation of said [3]. It is a figure which shows an example of implementation of said [4]. It is a figure which shows an example of implementation of said [5]. It is a figure which shows an example of implementation of said [6]. It is a figure which shows an example of implementation of said [7]. It is a figure which shows an example of implementation of said [7]. It is a figure which shows an example of implementation of said [8]. It is a figure which shows an example of implementation of said [9].

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be specifically described, but the present invention is not limited to the following description. Moreover, although an example of implementation of this invention is shown in FIGS. 1-10 by the batch system, this is for demonstrating invention easily and this invention is not limited to a batch system. .

<Short carbon fiber (A)>
The carbon short fiber is a short fiber obtained by cutting a carbon fiber into a specific length in a range of 1 mm to 20 cm. The carbon fiber used as the carbon short fiber can be used regardless of the raw material, but polyacrylonitrile (hereinafter referred to as PAN). It is preferable to include one or more carbon fibers selected from system carbon fibers, pitch system carbon fibers, rayon system carbon fibers, and phenol system carbon fibers, and include PAN system carbon fibers or pitch system carbon fibers. More preferred. The average diameter of the short carbon fibers is preferably about 3 to 30 μm, more preferably 4 to 20 μm, and still more preferably 4 to 12 μm. Within this range, the surface smoothness and conductivity as a porous electrode substrate are good.

  The average length of the short carbon fibers is preferably about 2 to 20 mm, more preferably about 2 to 12 mm. Within this range, the dispersibility during sheet formation and the mechanical strength as a porous electrode substrate are increased.

  The polyacrylonitrile-based carbon fiber is manufactured using a polymer mainly composed of acrylonitrile as a raw material. Specifically, a spinning process for spinning PAN-based fibers, a flameproofing process in which the fibers are heated and fired in an air atmosphere at 200 to 400 ° C. to convert them into oxidized fibers, and in an inert atmosphere such as nitrogen, argon, and helium In addition, the carbon fiber can be obtained through a carbonization step of carbonizing by heating to 300 to 2500 ° C., and is suitably used as a composite material reinforcing fiber. Therefore, it is possible to form a carbon sheet having a higher strength and a higher mechanical strength than other carbon fibers.

<Reticulated carbon fiber (B)>
The reticulated carbon fiber (B) is a carbonaceous fiber that joins the short carbon fibers (A) to each other, and is present in a state of being bent or curved at the joint, each forming a network structure. Yes. The reticulated carbon fiber (B) is obtained by carbonizing the precursor fiber (b) by heating. The short carbon fiber (A) is bound by the reticulated carbon fiber (B) by mixing and firing the short carbon fiber (A) and the precursor fiber (b).

  The content of the reticulated carbon fiber (B) in the porous electrode substrate is preferably 10 to 90% by mass. In order to maintain sufficient electrical conductivity and mechanical strength of the porous electrode substrate, the content of the reticulated carbon fiber (B) is more preferably 15 to 80% by mass.

<Precursor fiber (b)>
As the precursor fiber (b), one or both of the carbon fiber precursor short fiber (b1) and the fibrillar carbon precursor fiber (b2) can be used. A fibrillar carbon precursor fiber (b2) is preferred.

<Carbon fiber precursor short fiber (b1)>
The carbon fiber precursor short fiber (b1) is obtained by cutting a long fiber-like carbon fiber precursor fiber prepared using a polymer (for example, an acrylic polymer) described later into an appropriate length within a range of 1 mm to 20 cm. Can be. The average fiber length of the carbon fiber precursor short fibers (b1) is preferably 2 mm or more and 20 mm or less, more preferably 2 mm or more and 12 mm or less from the viewpoint of dispersibility. The average fiber length can be measured with an optical microscope and an electron microscope. Although the cross-sectional shape of the carbon fiber precursor short fiber (b1) is not particularly limited, a high roundness is preferable from the viewpoint of mechanical strength after carbonization and production cost. In addition, the average diameter of the carbon fiber precursor short fibers (b1) is preferably 5 μm or less from the viewpoint of suppressing breakage due to shrinkage during carbonization. The average fiber diameter (diameter) can be measured with an optical microscope and an electron microscope.

  As the carbon fiber precursor short fiber (b1), it is preferable to use a polymer having a remaining mass of 20% by mass or more in the step of carbonization treatment. Examples of such polymers include acrylic polymers, cellulose polymers, and phenolic polymers. 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.

The carbon fiber precursor short fibers (b1) may be one type, or a plurality of types having different fiber diameters and polymer types. Mixing ratio of these carbon fiber precursor short fibers (b1), fibrillar carbon precursor fibers (b2) described later, and carbon short fibers (A), 200 ° C. or more and 30
Depending on the presence or absence of the oxidation treatment at 0 ° C. or lower, the ratio of the net carbon fiber (B) remaining in the finally obtained porous electrode substrate can be adjusted.

<Acrylic polymer used for carbon fiber precursor short fiber (b1)>
The acrylic polymer 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.

  The weight average molecular weight of the acrylic polymer is not particularly limited, but is preferably from 50,000 to 1,000,000. When the weight average molecular weight of the acrylic polymer 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 of the acrylic polymer 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.

<Fibrous carbon precursor fiber (b2)>
As the fibrillar carbon precursor fiber (b2), for example, the following can be used. Carbon precursor fiber (b2-1) having a structure in which a large number of fibrils having a diameter of several μm or less (for example, 0.1 to 3 μm) are branched from a fibrous trunk having a diameter of 100 μm or less, or a carbon precursor fibrillated by beating Short body fibers (b2-2) can be used. Hereinafter, the two fibrillar carbon precursor fibers (b2) may be referred to as fibers (b2-1) and fibers (b2-2), respectively.

  By using these fibrillar carbon precursor fibers (b2), the short carbon fibers (A) and the fibrillar carbon precursor fibers (b2) are entangled well in the precursor sheet, and handling properties and mechanical strength are excellent. It becomes easy to obtain a precursor sheet. Although the freeness of the fibrillar carbon precursor fiber (b2) is not particularly limited, the use of fibrillar fibers having a low freeness generally improves the mechanical strength of the precursor sheet. There is a tendency that the gas permeability of gas decreases. Since the drainage of the slurry is changed by using the fibrillar carbon precursor fiber (b2), the freeness and mixing of the fibrillar carbon precursor fiber (b2) are adjusted so that the drainage of the slurry is 80 to 300 ml. It is preferable to adjust the ratio.

  As the fibrillar carbon precursor fiber (b2), one type of fiber (b2-1) or one type of fiber (b2-2) may be used, and the freeness, fiber diameter, polymer type, etc. are different. A plurality of these fibers may be used in combination.

  Hereinafter, the two fibrillar carbon precursor fibers (b2) will be described in detail.

<Fiber (b2-1)>
The polymer used for the fiber (b2-1) preferably has a residual mass of 20% by mass or more in the carbonization treatment step. Examples of such polymers include acrylic polymers, cellulose polymers, and phenolic polymers. Considering the spinnability, the short carbon fibers (A) can be bonded to each other from low temperature to high temperature, the remaining mass at the time of carbonization is large, and the entanglement with the short carbon fibers (A) and the sheet strength are taken into consideration. It is preferable to use an acrylic polymer containing 50% by mass or more of units. As the acrylic polymer, the same polymer as the carbon fiber precursor short fiber (b1) can be used.

  Although the manufacturing method of a fiber (b2-1) is not specifically limited, It is preferable to manufacture using the injection coagulation method with easy control of drainage. The fiber (b2-1) by the jet coagulation method can be manufactured by the following method, for example.

  First, a spinning stock solution is prepared by dissolving an acrylonitrile-based copolymer in a solvent. As this solvent, for example, dimethylamide, dimethylformamide, dimethylsulfoxide and the like can be used. Then, the spinning solution is passed through the spinning outlet and discharged into the mixing cell. At the same time, water vapor is ejected into the mixing cell at an angle of 0 degree or more and less than 90 degrees with respect to the discharging line direction of the spinning solution. The acrylonitrile copolymer is solidified under a shear flow rate. A fiber (b2-1) is obtained by discharging the formed solidified body together with the solvent and water vapor from the mixing cell into the solidified liquid. As the coagulation liquid, water or a mixed liquid of water and the solvent can be used.

  The fiber (b2-1) thus obtained has a fibril part in which fibers having a small fiber diameter gather and a core part (stem) having a thick fiber diameter solidified without much contact with water vapor. The fibril part of the fiber (b2-1) has good entanglement with the short fiber A and the fibril part of the fiber (b2-1), and the core part of the fiber (b2-1) expresses the strength as a binder. Can do.

  The fiber diameter of the fibril part of the fiber (b2-1) is preferably 2 μm or less in order to improve the entanglement with the short carbon fiber to be mixed.

  The core part preferably has a diameter of 100 μm or less from the viewpoint of homogenization of the porous electrode substrate. By setting the diameter to 100 μm or less, the uneven distribution of the fibers (b2-1) can be easily suppressed, and the short carbon fibers A can be easily bound by a relatively small amount of fibers (b2-1). Moreover, it is preferable that the diameter of a core part is 10 micrometers or more from a viewpoint of expressing intensity | strength.

  From the viewpoint of the function that the fiber (b2-1) is entangled with the short carbon fiber A, it is preferable that a plurality of fibril parts of the fiber (b2-1) exist for one core part, and the fibrils for one core part. It is considered that the more parts, the better.

  In one fiber (b2-1), it is preferable that the thickness of the core part is constant or changes steplessly. By using such a fiber (b2-1), it is possible to easily prevent the stepped portion from being weakened by a stepwise change in the thickness of the core portion, and to easily prevent the strength from being lowered. Can do. In addition, when manufacturing a fiber (b2-1) by the said method, it may be difficult to keep the thickness of a core part constant by water vapor | steam scattering randomly, and the thickness of a core part may change. is there. However, since a gradual change in the thickness of the core portion tends to be seen when the water vapor to be sprayed cools into droplets, the core portion can be obtained by increasing the water vapor ejection pressure and temperature. Can be easily prevented from changing in steps.

<Fiber (b2-2)>
The fiber (b2-2) can be obtained by beating a long-fiber easily split sea-island composite fiber into an appropriate length and beating it with a refiner, a pulper, or the like. Long-fiber easy split sea-island composite fibers can be manufactured using two or more different types of polymers that are soluble in a common solvent and incompatible, and at least one type of polymer is carbonized. The residual mass in the treatment step is preferably 20% by mass or more. Among the polymers used for the easily splittable sea-island composite fibers, those having a residual mass in the carbonization treatment step of 20% by mass or more include acrylic polymers, cellulose polymers, and phenolic 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.

  As the acrylic polymer, the same polymer as the carbon fiber precursor short fiber (b1) can be used.

  When one of the polymers used for the easily splittable sea-island composite fiber is a polymer having a residual mass of 20% by mass or more in the carbonization treatment step, the above-mentioned acrylic polymer is used as the other polymer. It is desirable that a spinning dope that dissolves in the same solvent as the acrylic polymer and dissolves both polymers stably exists. That is, it is desirable that the other polymer is incompatible with the acrylic polymer when dissolved in the same solvent as the acrylic polymer, and has a miscibility enough to form a sea-island structure during spinning. It is. This makes it possible to easily prevent inhomogeneity of the fiber that occurs when the degree of incompatibility of the two polymers is large when used as a spinning stock solution, and to easily prevent yarn breakage during spinning. Fiber shaping can be facilitated. In addition, it is desirable that other polymers are poorly soluble in water, so that when wet spinning, it is easy to prevent other polymers from dissolving in water and falling off in the coagulation tank and washing tank. Can do.

  Other polymers that satisfy these requirements include, for example, polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, polyvinyl pyrrolidone, cellulose acetate, acrylic resin, methacrylic resin, phenolic resin, etc. Resins and methacrylic resins are preferred from the viewpoint of the balance of demands described above. The other polymer may be one type or two or more types.

  The splittable sea-island composite fiber used for the fiber (b2-2) can be produced by a normal wet spinning method. First, a spinning stock solution is prepared by dissolving an acrylic polymer and another polymer in a solvent. Alternatively, a spinning stock solution obtained by dissolving an acrylic polymer in a solvent and a spinning stock solution obtained by dissolving another polymer in a solvent may be mixed with a static mixer or the like to obtain a spinning stock solution. As the solvent, dimethylamide, dimethylformamide, dimethyl sulfoxide and the like can be used. An easily split fiber sea-island composite fiber can be obtained by supplying these spinning stock solutions to a spinning machine, spinning from a nozzle, and performing wet heat drawing, washing, drying and dry heat drawing.

  The cross-sectional shape of the easily splittable sea-island composite fiber is not particularly limited. In order to suppress dispersibility and breakage due to shrinkage at the time of carbonization, the fineness of the easily split sea-island composite fiber is preferably 1 dtex or more and 10 dtex or less. The average fiber length of the splittable sea-island composite fiber is preferably 1 mm or more and 20 mm or less from the viewpoint of dispersibility after beating.

The easily splittable sea-island composite fiber is beaten by peeling of the phase separation interface by a mechanical external force, and at least a part thereof is split and fibrillated. The beating method is not particularly limited, and for example, fibrillation can be performed by a refiner, a pulper, a beater, or a jet of pressurized water (water jet punching). When beating a splittable sea-island composite fiber by mechanical external force by peeling of the phase separation interface, the fibrillation state changes depending on the beating method and beating time. As a method for evaluating the degree of fibrillation, freeness evaluation (JIS P8121 (pulp freeness test method: Canadian standard type)) can be used. The freeness of the fiber (b2-2) is not particularly limited.

<Resin carbide (C)>
Resin carbide is a carbide that binds between short carbon fibers (A) and between short carbon fibers (A) and reticulated carbon fibers (B), and uses a carbon material obtained by carbonizing the resin by heating. Can do. As the resin (c) that can be carbonized by heating, it is known that carbon short fibers (A) and carbon short fibers (A) and reticulated carbon fibers (B) can be bound at the stage of carbonization. It can be used by appropriately selecting from these resins. From the viewpoint of easily remaining as a conductive substance after carbonization, the resin (c) is preferably a phenol resin, an epoxy resin, a furan resin, pitch, or the like, and particularly preferably a phenol resin having a high carbonization rate upon carbonization by heating. . As the phenol resin, a resol type phenol resin obtained by reaction of phenols and aldehydes in the presence of an alkali catalyst can be used. In addition, a novolac type phenolic resin showing solid heat-fusibility, which is produced by a reaction of phenols and aldehydes under an acidic catalyst by a known method, can be dissolved and mixed in a resol type flowable phenolic resin. In this case, a self-crosslinking type containing a curing agent such as hexamethylenediamine is preferred. As the phenol resin, a phenol resin solution dissolved in a solvent of alcohol or ketones, a phenol resin dispersion liquid dispersed in a dispersion medium such as water, or the like can be used.

  It is also preferable to mix a conductive substance in the resin carbide to further improve the conductivity. The conductive substance is preferably a carbonaceous material such as carbonaceous milled fiber, carbon black, acetylene black, or graphite powder from the viewpoint of conductivity and acid resistance. The mixing amount of the conductive substance in the resin (c) that can be carbonized by heating is preferably 1 to 10% by mass with respect to the resin. If the mixing amount is less than 1% by mass, it is disadvantageous in that the effect of improving the conductivity is small, and if it exceeds 10% by mass, the effect of improving the conductivity tends to saturate, and the cost increases. It is disadvantageous in terms.

  The content of the resin carbide (C) in the porous electrode substrate is preferably 10 to 90% by mass. In order to maintain sufficient conductivity and mechanical strength of the porous electrode substrate, the content of the resin carbide (C) is more preferably 15 to 80% by mass.

<Dehydration modifier>
The dehydrating property adjusting agent is not particularly limited, but it is preferable to use polyacrylamide, polyethylene oxide, carboxymethyl cellulose, or the like from the viewpoints of dehydrating property and cost in the paper making process. Moreover, when producing a precursor sheet | seat by a wet method, the density | concentration of the dehydration modifier in a dispersion medium will be 0.1-0.01 g / L in the slurry (slurry for papermaking (C)) used at a papermaking process. It is preferable to add so as not to generate a fiber bundle in which the short carbon fibers (A) are concentrated in the precursor sheet, and to reduce utility during dehydration. More preferably, the amount is 0.08 to 0.02 g / L. If the concentration of the dehydrating modifier is too low, a fiber bundle in which the short carbon fibers (A) dispersed in the slurry are converged is generated again. If the concentration of the dehydrating modifier is too high, the dispersion medium is formed from the slurry. It is difficult to dehydrate water, the utility increases, the manufacturing cost of the precursor sheet increases, and the sheet formation is not stable because the dewatering position is not constant when continuously forming sheets. Getting worse.

  In the present invention, the dehydrating modifier is added to the dispersion medium (A), but may also be added to the slurry (D) or the slurry (A-2). In that case, the total amount of the dehydrating modifier added to the dispersion medium (A) and the slurry (D), or the total amount of the dehydrating modifier added to the dispersion medium (A) and the slurry (A-2), The amount is adjusted to 0.1 to 0.01 g / L in the papermaking slurry (C). At this time, if too little dehydrating modifier is added to the dispersion medium (A), a fiber bundle in which the carbon short fibers (A) dispersed in the slurry (A) are re-focused is generated. In B), it is preferable to add a dehydrating modifier in an amount of 0.01 g / L or more.

<Porous electrode substrate precursor sheet>
The porous electrode substrate precursor sheet is obtained by dispersing short carbon fibers (A) and precursor fibers (b), and may or may not form a three-dimensional entangled structure. The entanglement process for forming the three-dimensional entangled structure will be described later.

  The mass ratio of the short carbon fibers (A) constituting the porous electrode substrate precursor sheet in the sheet is the total amount of the fiber material from the viewpoint of the sheet strength expression of the precursor electrode and the porous electrode substrate after heat treatment. 40% or more and 90% or less is preferable.

  The precursor sheet 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 precursor sheet.

  If necessary, wet papermaking can be performed using an organic polymer compound as a binder. This organic polymer compound plays a role as a binder (glue) that holds the components together in a precursor sheet containing carbon short fibers (A) or carbon short fibers (A) and precursor fibers (b). Have. As this organic polymer compound, polyvinyl alcohol (PVA), polyvinyl acetate, or the like can be used. In particular, polyvinyl alcohol is preferred because it has excellent binding power in the paper making process and the short carbon fibers are less likely to fall off. In the present invention, it is also possible to use this organic polymer compound in a fiber shape.

  In the present invention, the “total amount of fiber material” refers to the amount of short carbon fibers (A) and precursor fibers (b) present in the sheet. For example, when an organic polymer compound is used in the form of a fiber as the binder, the mass of the fibrous binder does not add to the mass of the carbon short fiber (A) and the precursor fiber (b), but the carbon short fiber (A) The mass ratio with respect to the total amount of fiber material is determined.

In the case of using the precursor fiber (b), the carbon short fiber (A) and the precursor fiber (b) (for example, the fibrillar carbon precursor fiber (b2) can be formed without using the organic polymer compound as a binder. A precursor sheet can be obtained by moderate entanglement with)).
The basis weight of the precursor sheet is preferably 10 g / m 2 or more and 200 g / m 2 or less from the viewpoints of handling properties of the precursor sheet and gas permeability, conductivity, and handling properties when used as a porous electrode substrate.
The thickness of the precursor sheet is preferably 20 μm or more and 500 μm or less, more preferably 50 μm or more and 400 μm or less, from the viewpoint of gas permeability, conductivity, and handling properties.

  When the precursor fiber (b) is used, the network carbon fiber (B) in the porous electrode substrate finally obtained depending on the type, the mixing ratio with the short carbon fiber (A), and the presence or absence of oxidation treatment. The remaining proportion can be adjusted.

  The presence of a bundle of short carbon fibers (A) in the precursor sheet causes local gas diffusivity and conductive spots when used as a porous electrode substrate, and is incorporated into a fuel cell. As a result, the power generation performance becomes uneven, which greatly affects battery durability. Therefore, it is preferable that the fiber bundle ratio, which is the ratio of the fiber bundles in which the short carbon fibers (A) in the precursor sheet are converged, is 2 or less.

<How to find the fiber bundle ratio>
(I) Light is applied from the back and top surfaces of the porous electrode substrate precursor sheet, and a 15 cm × 15 cm range is photographed using a digital camera having 2 million pixels or more.
(Ii) Based on the photograph taken in (i) above, the number of fiber bundles in a state where a plurality of short carbon fibers (A) are bundled in the range of 15 cm × 15 cm is measured.
(Iii) The above measurements (i) and (ii) are performed at any three locations on the porous electrode substrate precursor, and the average value is defined as the fiber bundle ratio.

<Porous electrode substrate>
The porous electrode substrate of the present invention comprises a structure in which short carbon fibers (A) dispersed in a structure are bound by network carbon fibers (B), or a short carbon dispersed in a structure. The fibers (A) are bound together by the reticulated carbon fibers (B), and between the carbon short fibers (A) and between the carbon short fibers (A) and the reticulated carbon fibers (B) by the resin carbide (C). Is a structure in which carbon short fibers (A) are bound by resin carbide (C).

The porous electrode substrate can take a sheet shape, a spiral shape, or the like. When formed into a sheet, the basis weight of the porous electrode substrate is preferably about 15 to 100 g / m ² , the porosity is preferably about 50 to 90%, and the thickness is preferably 20 μm to 400 μm, more preferably 50 μm or more and 300 μm or less.

The gas air permeability of the porous electrode substrate is preferably 500 to 30000 ml / hr / cm ² / mmAq. Moreover, it is preferable that the electrical resistance (penetration direction resistance) of the thickness direction of a porous electrode base material is 50 m (ohm) * cm < ² > or less. In addition, the measuring method of the gas permeability of a porous electrode base material and penetration direction resistance is mentioned later.

  If there is a bundle of short carbon fibers (A) bundled in the porous electrode substrate, local gas diffusibility and conductivity spots will cause spots in the power generation performance when assembled in a fuel cell. It has a great effect on battery durability. Therefore, it is preferable that the fiber bundle ratio, which is the ratio of the fiber bundles in which the short carbon fibers (A) in the porous electrode substrate are focused, is 2 or less.

  When a fiber bundle in which short carbon fibers (A) are concentrated is present in the porous electrode substrate of the present invention, local gas diffusibility and conductive spots are the cause, and power generation performance in a state where it is incorporated in a fuel cell. Spots appear on the battery, greatly affecting battery durability. Therefore, it is preferable that the fiber bundle ratio, which is the ratio of the fiber bundles in which the short carbon fibers (A) in the porous electrode substrate are focused, is 2 or less.

<How to find the fiber bundle ratio>
(I) Light is applied from the back and top surfaces of the porous electrode base material, and a range of 15 cm × 15 cm is photographed using a digital camera having 2 million pixels or more.
(Ii) Based on the photograph taken in (i) above, the number of fiber bundles in a state where a plurality of short carbon fibers (A) are bundled in the range of 15 cm × 15 cm is measured.
(Iii) The measurements (i) and (ii) above are performed at any three locations on the porous electrode substrate, and the average value is defined as the fiber bundle ratio.

<Production method of the present invention>
The present invention is a method for producing a porous electrode substrate precursor sheet by paper-making a fiber mixed slurry, and further using a porous electrode substrate precursor sheet produced by the production method. This is a method of manufacturing a material.

  As a method for producing a porous electrode substrate precursor sheet, specifically, a porous electrode substrate precursor is made by paper-making a fiber mixed slurry comprising a mixture containing short carbon fibers (A) and precursor fibers (b). In the method for producing a body sheet, the following (I) to (IV) are carried out, which is a method for producing a porous electrode substrate precursor sheet. In the present invention, before and after each of the operations (I) to (IV), another operation may be performed as long as the effect of the present invention is not impaired.

  (I) A dehydrating modifier is mixed with the dispersion medium (A) to obtain a dispersing medium (B) containing the dehydrating modifier.

  (II) The dispersion medium (B) obtained in the above (I) and the short carbon fiber (A) are mixed to obtain a slurry (A).

  (III) The slurry (A) obtained in (II) and the precursor fiber (b) are mixed to obtain a slurry (B).

  (IV) A porous electrode base material comprising a paper mixture of the slurry (B) obtained in (III) as a papermaking slurry (C) and comprising a fiber mixture of carbon short fibers (A) and precursor fibers (b) A precursor sheet is obtained.

  In the above (I) to (IV), the following conditions are satisfied.

  In the above (I), the amount of the dehydrating regulator is 0.01 to 0.1 g / L per 1 L of the papermaking slurry (C) dispersion medium.

  In said (II), the quantity of a short carbon fiber (A) is an quantity used as 1-10g per 1L of dispersion media of a slurry (A).

  In the above (III), the amount of the precursor fiber (b) is an amount satisfying the following formula 1 by mass ratio.

(Formula 1)
0.1 ≦ precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A)) ≦ 0.6
In the present invention, by adding short carbon fibers to a dispersion medium containing a dehydrating modifier, the short carbon fibers are promoted to be uniformly dispersed in the dispersion medium, and a fiber bundle in which the short carbon fibers are converged is formed. Can be reduced.

<< (I) A dehydrating modifier is mixed with a dispersion medium (A) to obtain a dispersing medium (B) containing a dehydrating modifier. >>
In the present invention, a dehydrating modifier is first mixed with the dispersion medium (A) to obtain a dispersing medium (B) containing the dehydrating modifier. The amount of the dehydrating modifier is 0.01 to 0.1 g / L per 1 L of the papermaking slurry (C) dispersion medium. If the amount of the dehydrating modifier is too small, a fiber bundle in which the short carbon fibers (A) dispersed in the slurry are converged is generated. If the amount is too large, water as a dispersion medium can be dehydrated from the slurry during paper making. In addition to increasing the utility and increasing the manufacturing cost of the precursor sheet, the sheet formation deteriorates because the dewatering position is not constant when continuously forming sheets. A preferable amount of the dehydrating modifier is an amount of 0.01 to 0.1 g / L per 1 L of the papermaking slurry (C) dispersion medium.

  The amount of the dehydrating modifier that is 0.01 to 0.1 g / L per 1 L of the dispersion medium of the papermaking slurry (C) is calculated by the amount of the dehydrating modifier added.

  Even when the slurry (B-1) is made as the papermaking slurry (C) instead of the slurry (B) in (IV), the amount of the dehydrating regulator in (I) is the same as that for the papermaking slurry. This is an amount calculated based on (C).

  The amount of the dehydrating modifier in the dispersion medium (B) is 0 per liter of the dispersion medium of the papermaking slurry (C) in terms of enhancing the dispersibility of the short carbon fibers (A) in the slurry (A) described later. It is the conditions which satisfy | fill the quantity used as 0.01-0.1 g / L, and also it is preferable that it is 0.01 g / L or more in a dispersion medium (B).

<< (II) The dispersion medium (B) obtained in the above (I) and the short carbon fiber (A) are mixed to obtain a slurry (A). >>
In (I), a dispersion medium (B) containing a dehydrating modifier is prepared in advance, and this is mixed with short carbon fibers (A). Mixing the dispersion medium (A) that does not contain the dehydrating modifier and the short carbon fibers (A) will inhibit the short carbon fibers from being uniformly dispersed in the dispersing medium, and then add the dehydrating modifier. Even if it does, the fiber bundle which the short carbon fiber gathered will generate | occur | produce. Further, even when the short carbon fibers (A) and the precursor fibers (b) are simultaneously added to the dispersion medium (A), the short carbon fibers are partially inhibited from being uniformly dispersed in the dispersion medium. Then, even if a dehydrating modifier is added thereafter, a fiber bundle in which short carbon fibers are bundled is generated. A dispersion medium (B) containing a dehydration modifier is prepared in advance, and by mixing this with the carbon short fibers (A), the carbon short fibers are promoted to be uniformly dispersed in the dispersion medium, and It is possible to reduce fiber bundles in which short carbon fibers are bundled.

  In (II) of the present invention, when the carbon short fiber (A) and the precursor fiber (b) are mixed together in the dispersion medium (B), the carbon short fiber (A) and the precursor fiber (b) are mixed. Further, the short carbon fibers are uniformly dispersed in the dispersion medium, and a fiber bundle in which the short carbon fibers are converged is generated. Accordingly, in (II), the short carbon fibers (A) are mixed with the dispersion medium (B) without mixing the precursor fibers (b) with the dispersion medium (B).

  The amount of the short carbon fibers (A) is 1 to 10 g per 1 L of the dispersion medium of the slurry (A). If the amount of short carbon fibers (A) is too small, a large amount of papermaking slurry (C) is required when preparing the precursor sheet, resulting in a decrease in productivity. If the amount is too large, short carbon fibers are uniformly dispersed in the dispersion medium. Inhibiting this, a fiber bundle in which short carbon fibers are converged is generated. A preferable amount of the short carbon fiber (A) is an amount of 1 to 10 g / L per 1 L of the dispersion medium of the slurry (A).

  The amount of the short carbon fiber (A) that is 1 to 10 g per liter of the dispersion medium of the slurry (A) is calculated by the amount of the short carbon fiber (A) added.

  Note that the amount of the short carbon fibers (A) in (I) is the amount of the slurry even if the slurry (B-1) is made as the papermaking slurry (C) instead of the slurry (B) in (IV). This is an amount calculated based on (A).

<< (III) The slurry (A) obtained in (II) and the precursor fiber (b) are mixed to obtain the slurry (B) >>
In the present invention, slurry (A) in which short carbon fibers (A) are dispersed in (II) is produced in advance, and precursor fiber (b) is mixed with this to obtain slurry (B). As described above, when the precursor fiber (b) is put together with the short carbon fiber (A) into the dispersion medium (A) containing the dehydrating modifier (that is, the dispersion medium (B)), the short carbon fiber (A) and The precursor fibers (b) are converged with each other, and further, the carbon short fibers are prevented from being uniformly dispersed in the dispersion medium, so that a fiber bundle in which the carbon short fibers are converged is generated. The slurry (A) in which the carbon short fibers (A) are dispersed in advance is manufactured, and the precursor fibers (b) are mixed therewith to promote the uniform dispersion of the carbon short fibers in the dispersion medium. And generation | occurrence | production of the fiber bundle which the carbon short fiber converged can be suppressed.

  The amount of the precursor fiber (b) is an amount that satisfies the following formula 1 in terms of mass ratio.

(Formula 1)
0.1 ≦ precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A)) ≦ 0.6

If the value of “precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A))” in Formula 1 is too small, the amount of reticulated carbon fiber (B) formed is reduced, and the porous electrode The strength of the substrate is greatly reduced. Moreover, when too large, the carbon short fiber (A) which suppresses shrinkage | contraction of the precursor fiber (b) at the time of carbonization will decrease, and the sheet | seat will be generate | occur | produced by contraction of a sheet.
Formula 1 is preferably Formula 1-1 below.

(Formula 1-1)
0.2 ≦ precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A)) ≦ 0.5

Even when the paper (S-1) is used as the papermaking slurry (C) instead of the slurry (B) in (IV), the amount of the precursor fiber (b) is expressed by the formula (1). The amount calculated on the basis.

  In (III), from the viewpoint of suppressing the generation of fiber bundles in which short carbon fibers are converged, and further improving the formation and productivity of the precursor sheet, slurry (B) is dispersed with dispersion medium (A-3). After dilution, 0.8 to 1.8 g of fiber material (carbon short fiber (A) + precursor fiber (b) per liter of dispersion medium (mixed dispersion medium of dispersion medium (B) and dispersion medium (A-3)) It is preferable to obtain a slurry (B-1) in which)) is mixed.

  The amount of the dispersion medium (B) and the dispersion medium (A-3) may be determined so as to satisfy the conditions of the slurry (B-1).

  Examples of the method of mixing the slurry (A) and the precursor fiber (b) in (III) include the following methods <1> to <4>.

<1> A method in which the precursor fiber (b) is directly charged and mixed in the slurry (A). <2> The dispersion medium (A-1) not containing the dehydrating modifier and the precursor fiber (b) are mixed. The slurry (D) is mixed with the slurry (A) obtained in (II). Since the slurry (A) contains a dehydrating regulator, the precursor fiber (b) Rather than directly mixing the slurry with the slurry (A), the precursor fiber (b) is dispersed in advance in the dispersion medium (A-1) containing no dehydrating modifier to form the slurry (D), and then mixed with the slurry (A). It is possible to suppress the generation of the fiber bundle of the precursor fiber (b).

  The slurry (D) is obtained by mixing the dispersion medium (A-1) substantially free of a dehydrating modifier and the precursor fiber (b). When the dispersion medium (A-1) contains a dehydrating modifier, it is easy to inhibit the precursor fiber (b) from being uniformly dispersed in the dispersion medium, and the fiber bundle of the precursor fiber (b). Is likely to occur. The fact that the dehydrating modifier is substantially not included is that the precursor fibers (b) are likely to be uniformly dispersed in the dispersion medium, and the fiber bundles of the precursor fibers (b) are likely to be generated. Although it is allowed to contain a dehydrating modifier as long as it does not attack, it is more preferable that no dehydrating modifier is contained.

  The amount of the dispersion medium (A-1) not containing the dehydrating modifier is adjusted so that the dehydrating modifier and the short carbon fibers (A) and the precursor fibers (b) have the aforementioned concentrations and ratios.

  In <2>, after the precursor fibers (b) are uniformly dispersed in the dispersion medium, the precursor fibers (b) are converged again, and a fiber bundle of the precursor fibers (b) is likely to be generated. From the viewpoint of suppressing this, after obtaining the slurry (D), a dehydrating modifier may be added to the slurry (D). At that time, a dehydrating modifier diluted with the dispersion medium (A-2) may be added to the slurry (D). Further, the total amount of the dispersion medium (B), the dispersion medium (A-1) and the dispersion medium (A-2) is set to be large, and the dispersion medium (dispersion medium (B), dispersion medium (A-1) and dispersion medium ( A-2) mixed dispersion medium) It is also possible to obtain slurry (B-1) in which 0.8 to 1.8 g of fiber material (carbon short fiber (A) + precursor fiber (b)) is mixed per liter. it can.

<3> Dispersion medium (A-1) not containing a dehydrating modifier and precursor fiber (b) are mixed to form slurry (D), and slurry (D) obtained in (II) is slurry (A) ) And a method of mixing with the dispersion medium (A-3) In this method, the dispersion medium (dispersion medium (B), dispersion medium (A-1) and dispersion medium (A-3) mixed dispersion medium) is 0 per liter. A slurry (B-1) in which 8 to 1.8 g of fiber material (carbon short fiber (A) + precursor fiber (b)) is mixed is obtained. What is necessary is just to determine each quantity of a dispersion medium (B), a dispersion medium (A-1), and a dispersion medium (A-3) so that this condition may be satisfy | filled.

  This method can reduce the amount of adjusting the slurry (A) and the slurry (D), and is preferable from the viewpoint of productivity in continuous production.

  In this method, it is preferable to simultaneously mix the slurry (D), the slurry (A), and the dispersion medium (A-3). By mixing at the same time, the equipment during mixing can be simplified.

  In <3>, after the precursor fibers (b) are uniformly dispersed in the dispersion medium, the precursor fibers (b) are converged again, and a fiber bundle of the precursor fibers (b) is easily generated. From the viewpoint of suppressing this, after obtaining the slurry (D), a dehydrating modifier may be added to the slurry (D). At that time, a dehydrating modifier diluted with the dispersion medium (A-2) may be added to the slurry (D). When diluted with the dispersion medium (A-2), the resulting slurry (B-1) is dispersed into the dispersion medium (dispersion medium (B), dispersion medium (A-1), dispersion medium (A-3) and dispersion medium ( A-2) Mixed Dispersion Medium) A mixture of 0.8 to 1.8 g of fiber material (carbon short fiber (A) + precursor fiber (b)) per liter. What is necessary is just to determine each quantity of a dispersion medium (B), a dispersion medium (A-1), a dispersion medium (A-3), and a dispersion medium (A-2) so that this condition may be satisfy | filled.

<4> The dispersion medium (A-1) not containing the dehydrating modifier and the precursor fiber (b) are mixed to obtain a slurry (D-1), and the slurry (D-1) is obtained in (II). In this method, the total amount of the dispersion medium (B) and the dispersion medium (A-1) is set to be large, and the dispersion medium (dispersion medium (B) and dispersion medium (A-1)) is mixed. Mixed dispersion medium) A method of obtaining a slurry (B-1) in which 0.8 to 1.8 g of fiber material (carbon short fiber (A) + precursor fiber (b)) is mixed per liter. Slurry (B-1) is 0.8 to 1.8 g of fiber material (carbon short fiber (A) + precursor) per liter of dispersion medium (mixed dispersion medium of dispersion medium (B) and dispersion medium (A-1)) What is necessary is just to determine the quantity of each of a dispersion medium (B) and a dispersion medium (A-1) so that it may become a slurry with which the fiber (b)) was mixed.

  In <4>, after the precursor fibers (b) are uniformly dispersed in the dispersion medium, the precursor fibers (b) are converged again, and a fiber bundle of the precursor fibers (b) is easily generated. From the viewpoint of suppressing this, after obtaining the slurry (D-1), a dehydrating modifier may be added to the slurry (D-1). At that time, a dehydrating modifier diluted with the dispersion medium (A-2) may be added to the slurry (D-1). When diluted with the dispersion medium (A-2), the resulting slurry (B-1) is mixed with the dispersion medium (dispersion medium (B), dispersion medium (A-1), and dispersion medium (A-2). Medium) A fiber material (carbon short fiber (A) + precursor fiber (b)) of 0.8 to 1.8 g per liter is mixed. What is necessary is just to determine each quantity of a dispersion medium (B), a dispersion medium (A-1), and a dispersion medium (A-2) so that this condition may be satisfy | filled.

<Slurry for papermaking (C)>
When producing a precursor sheet by a wet method, a papermaking slurry (C) for sheeting is prepared by dispersing a fiber mixture containing short carbon fibers (A) and precursor fibers (b) in a dispersion medium. be able to.

  From the viewpoint of developing sheet strength of the precursor sheet and the porous electrode substrate after heat treatment, the mixing ratio of the short carbon fibers (A) in the papermaking slurry (C) is 40% or more by mass ratio with respect to the total amount of the fiber material. % Or less is preferable. More preferably, it is 50 to 80%.

  In the present invention, the “total amount of fiber material” refers to the amount of short carbon fibers (A) and precursor fibers (b) present in the papermaking slurry (C). For example, when an organic polymer compound is used in the form of a fiber as the binder, the mass of the fibrous binder does not add to the mass of the carbon short fiber (A) and the precursor fiber (b), but the carbon short fiber (A) The mass ratio with respect to the total amount of fiber material is determined.

  In the present invention, the “fiber concentration in the slurry” refers to the concentration of the short carbon fiber (A) and the precursor fiber (b) present in the sheet. For example, when an organic polymer compound is used in the form of a fiber as a binder, the mass of the fibrous binder is not added to the mass of the short carbon fiber (A) and the precursor fiber (b), and the fiber concentration in the slurry is Ask.

<Dispersion medium>
Examples of the dispersion medium that can be used in the present invention include a medium in which the precursor fiber (b) does not dissolve, such as water and alcohols such as ethanol and methanol. From the viewpoint of productivity, water is preferable. In the present invention, the dispersion medium (A), dispersion medium (A-1), dispersion medium (A-2), and dispersion medium (A-3) are each independently the specific dispersion medium (water, alcohol, etc.). ) Can be selected. The dispersion medium (A), the dispersion medium (A-1), the dispersion medium (A-2), and the dispersion medium (A-3) may be the same or different, but they are the same from the viewpoint of productivity. preferable.

<< (IV) Porous electrode comprising a paper mixture of the slurry (B) obtained in (III) as a papermaking slurry (C) and comprising a fiber mixture of carbon short fibers (A) and precursor fibers (b) Obtain substrate precursor sheet >>
In the present invention, paper is made as the papermaking slurry (C) using the slurry (B) obtained in (III). When the slurry (B-1) is obtained instead of the slurry (B) in (III), the slurry (B-1) is made as a papermaking slurry (C). By making paper, a porous electrode substrate precursor sheet made of a fiber mixture of short carbon fibers (A) and precursor fibers (b) is obtained. The other school soup electrode substrate precursor sheet is as described in the above <Porous electrode substrate precursor sheet>.

<Method for producing porous electrode substrate>
Further, the porous electrode substrate precursor sheet obtained by the above-described method for producing a porous electrode substrate precursor sheet is heated and pressurized, and the heated and pressurized porous electrode substrate precursor sheet is heated to 1000 ° C. or higher. A method for producing a porous electrode substrate that is carbonized at a temperature of 1 to obtain a porous electrode substrate is also one aspect of the present invention.

  An oxidation treatment of the heated and pressurized porous electrode substrate precursor sheet may be provided between the heating and pressing treatment and the carbonization treatment. Before the heating and pressing treatment, the porous electrode substrate precursor sheet is provided. The confounding process may be provided. Further, when the entanglement treatment is not provided, the carbonizable resin (c) can be applied to the porous electrode substrate precursor sheet between the entanglement treatment and the heat and pressure treatment when the entanglement treatment is provided. ) May be provided.

<< Heat and pressure treatment >>
A structure in which the short carbon fibers (A) in which the porous electrode base material is dispersed in the structure are sufficiently bound by the network carbon fibers (B), or the short carbon in which the porous electrode substrate is dispersed in the structure. The fibers (A) are sufficiently bound together by the reticulated carbon fibers (B), and between the carbon short fibers (A) and the carbon short fibers (A) and the reticulated carbon fibers (B) by the resin carbide (C). It is preferable to heat and pressure mold the precursor sheet at a temperature of less than 300 ° C. in order to obtain a structure in which the gap is sufficiently bound and to reduce thickness unevenness of the porous electrode substrate. Any technique can be applied to the heat and pressure molding as long as the technique can uniformly heat and mold the precursor sheet. For example, a method in which a smooth rigid plate is applied to both surfaces of the precursor sheet and heat-pressed, or a method using a continuous roll press device or a continuous belt press device can be mentioned.

  In the case of heating and press-molding a continuously produced precursor sheet, a method using a continuous roll press device or a continuous belt press device is preferable. Thereby, the carbonization process 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, and a method of pressing with a surface pressure by a hydraulic head press. The latter is preferred in that a smoother porous electrode substrate can be obtained.

  The temperature at the time of heat and pressure molding is sufficient to bond the short carbon fibers (A), the precursor fibers (b), and the resin (c), and the surface of the porous electrode substrate precursor sheet is effectively used. In order to make it smooth, it is preferably less than 300 ° C, more preferably 120 to 290 ° C.

The pressure at the time of heat and pressure molding is not particularly limited, but is preferably about 20 kPa to 10 MPa. 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 is too dense, or the like. is there.

  The time for heat and pressure molding can be, for example, 5 seconds to 10 minutes. When the precursor sheet is sandwiched between two rigid plates, or when heated and pressed by a continuous roll press device or a continuous belt press device, the precursor fiber (b) and / or resin (c ) Or the like is preferably applied in advance, or a release paper is preferably sandwiched between the precursor sheet and the rigid plate or roll or belt.

Even when one precursor sheet is molded during the heat and pressure molding, a plurality of precursor sheets may be superimposed and integrated.

<< Carbonization treatment >>
By the carbonization treatment, the precursor fibers (b) and / or the resin (c) are carbonized to form reticulated carbon fibers (B) and / or resin carbides (C). Thereby, the mechanical strength and electroconductivity of the porous electrode base material obtained are improved.

  The carbonization treatment is preferably performed in an inert gas in order to increase the conductivity of the obtained porous electrode substrate. The carbonization treatment is usually performed at a temperature of 1000 ° C. or higher. 1000-3000 degreeC is preferable and, as for the temperature range which carbonizes, 1000-2200 degreeC is more preferable. The time for performing the carbonization treatment is, for example, about 10 minutes to 1 hour. Further, before the carbonization treatment, pretreatment by firing in an inert atmosphere of about 300 to 800 ° C. can be performed.

  When carbonizing the continuously manufactured precursor sheet, it is preferable to continuously perform the carbonizing process over the entire length of the precursor sheet from the viewpoint of reducing the manufacturing cost. If the porous electrode substrate is made long, the productivity of the porous electrode substrate can be further increased, and the subsequent MEA (Membrane Electrode Assembly) production can also be continuously performed. Manufacturing cost can be easily 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.

  Moreover, in this invention, the heat-pressed porous electrode base material precursor sheet | seat can be oxidized between a heat press treatment and a carbonization process. The precursor sheet can be entangled before the heat and pressure treatment, and the porous electrode substrate precursor sheet can be entangled before the heat and pressure treatment. Furthermore, before the heat and pressure treatment, the porous electrode substrate precursor sheet can be impregnated with a carbonizable resin (c), and when the entanglement treatment is also performed, between the entanglement treatment and the heat and pressure treatment. The porous electrode substrate precursor sheet may be impregnated with a carbonizable resin (c).

<< Entanglement process >>
The entanglement process for entanglement of the short carbon fibers (A) or the short carbon fibers (A) and the precursor fibers (b) in the precursor sheet may be any method that forms an entangled structure, and is a known method. Can be implemented. For example, 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. The high-pressure liquid injection method is preferable because breakage of the short carbon fibers (A) in the entanglement process can be easily suppressed and moderate entanglement can be easily obtained. Hereinafter, this method will be described in detail.

  The high-pressure liquid jet processing method is a method in which a precursor sheet is placed on a substantially smooth support member and, for example, a liquid columnar flow, a liquid fan-shaped flow, a liquid slit flow, or the like sprayed at a pressure of 1 MPa is applied. The carbon fiber (A) in the precursor sheet or the carbon fiber (A) and the precursor fiber (b) are entangled with each other. Here, the support member having a substantially smooth surface is selected as necessary from the one in which the ejected liquid is quickly removed without being formed in the entangled structure body where the pattern of the support member can be obtained. Can be used. Specific examples thereof include 30-200 mesh wire nets, plastic nets or rolls.

  It is preferable from the viewpoint of productivity that the precursor sheet is manufactured on a support member having a substantially smooth surface, and then the high-pressure liquid injection treatment can be continuously performed because the precursor sheet is entangled.

  The liquid used for the high-pressure liquid jet treatment may be anything other than a solvent that dissolves the fibers constituting the precursor sheet, but it is usually preferable to use water or warm water. The hole diameter of each injection nozzle in the high-pressure liquid injection nozzle is preferably 0.03 mm or more and 1.0 mm or less, and 0.05 mm or more and 0.3 mm or less from the viewpoint that a sufficient confounding effect is obtained in the case of a columnar flow. More preferred. The distance between the nozzle injection hole and the laminate is preferably 0.5 cm or more and 5 cm or less. The pressure of the liquid is preferably 0.5 MPa or more, and more preferably 1.0 MPa or more. The confounding process may be performed in a single row or in a plurality of rows. When performing in a plurality of rows, it is effective to increase the pressure of the high-pressure liquid jet processing in the second and subsequent rows rather than the first row.

  The entanglement process by high-pressure liquid injection of the precursor sheet may be repeated a plurality of times. That is, after performing the high-pressure liquid injection process on the precursor sheet, the precursor sheet may be further laminated, and the high-pressure liquid injection process may be performed. Liquid ejection processing may be performed. These operations may be repeated.

  When continuously manufacturing the entangled structure precursor sheet, the high pressure liquid injection nozzle having one or more rows of nozzle holes is vibrated in the width direction of the sheet, resulting in the formation of a dense structure of the sheet in the sheet forming direction. It is possible to suppress the formation of a streak-like trajectory pattern. By suppressing the streak-like trajectory pattern in the sheet forming direction, the mechanical strength in the sheet width direction can be expressed. Further, when a plurality of high-pressure liquid jet nozzles having one or a plurality of rows of nozzle holes are used, the confounding structure precursor is controlled by controlling the frequency and the phase difference of the high-pressure liquid jet nozzles that vibrate in the width direction of the sheet. Periodic patterns appearing on the sheet can also be suppressed.

  By the entanglement treatment, the hand linkability of the precursor sheet and the porous electrode substrate is improved. Furthermore, the conductivity in the thickness direction of the porous electrode substrate is also improved.

  Next, in this invention, the process (4) of oxidizing the heat-pressed precursor sheet | seat can be included between the process (1) of heat-pressing, and the carbonization process (2). . From the viewpoints of fusing the short carbon fibers (A) well with the precursor fibers (b) and improving the carbonization rate of the precursor fibers (b), the heated and pressurized precursor sheet is oxidized. It is preferable to do. Hereinafter, the oxidation treatment process will be described in detail.

<< Oxidation treatment >>
The temperature of the oxidation treatment is preferably 200 ° C. or higher and lower than 300 ° C., and more preferably 240 ° C. or higher and 290 ° C. or lower from the viewpoint of improving the carbonization rate. The oxidation treatment time can be, for example, 1 minute to 2 hours. As oxidation treatment, continuous oxidation treatment by direct pressure heating using a heated perforated plate or continuous oxidation treatment by intermittent direct pressure heating using a heating roll or the like is low in cost and short carbon fiber (A) Is preferable in that it can be fused with the precursor fiber (b). When oxidizing the precursor sheet manufactured continuously, it is preferable to continuously oxidize the entire length of the precursor sheet. As a result, the carbonization treatment can be performed easily and continuously.

  Next, in the present invention, the precursor sheet can be impregnated with the resin (c) before the heat and pressure treatment. In this embodiment, since the carbon short fibers (A) and between the carbon short fibers (A) and the reticulated carbon fibers (B) can be bound with the resin carbide (C), the porous electrode base material hand Linkability is improved. Furthermore, the conductivity in the thickness direction of the porous electrode substrate is improved. The resin impregnation will be described in detail below.

<< Resin impregnation >>
In the present invention, the precursor sheet containing short carbon fibers described above is impregnated with a carbonizable resin or a mixture of a resin and a conductor, cured by heating and pressurization, and then carbonized to provide a porous fuel cell. An electrode substrate is used.

  As a method of impregnating the precursor sheet with resin or a mixture of a resin and a conductor, a method using a drawing device or a method of stacking a resin film on a carbon sheet is preferable. In the method using a squeezing device, a carbon sheet is impregnated in a resin solution or mixed solution, and the squeezing device applies the liquid to the entire carbon sheet uniformly, and the amount of liquid is adjusted by changing the roll interval of the squeezing device. It is a method to do. If the viscosity is relatively low, a spray method or the like can also be used.

  In the method using a resin film, first, a thermosetting resin is once coated on a release paper to obtain a thermosetting resin film. Thereafter, the film is laminated on a carbon sheet and subjected to heat and pressure treatment to transfer a thermosetting resin.

<Membrane-electrode assembly (MEA)>
The porous electrode substrate of the present invention can be suitably used for a membrane-electrode assembly. The membrane-electrode assembly is composed of a polymer electrolyte membrane, a catalyst layer, and a porous carbon electrode base material. A cathode side catalyst layer comprising a catalyst for oxidizing gas is provided on one surface of the polymer electrolyte membrane having proton conductivity. And an anode side catalyst layer made of a catalyst for fuel gas on the other surface, and a cathode side porous electrode substrate and an anode side porous electrode substrate are provided outside each catalyst layer. Yes.

<Solid polymer fuel cell>
The membrane-electrode assembly of the present invention can be suitably used for a polymer electrolyte fuel cell. The polymer electrolyte fuel cell includes a cathode side separator in which a cathode side gas flow path is formed and an anode side separator in which an anode side gas flow path is formed so as to sandwich a membrane-electrode assembly. Each separator is provided with an oxidizing gas inlet and an oxidizing gas outlet, and a fuel gas inlet and a fuel gas outlet.

  Hereinafter, the present invention will be described more specifically with reference to examples. Each physical property value in the examples was measured by the following method. “Part” means “part by mass”.

  Tables 1 and 2 are one table (sheet), but are divided into two for easy viewing.

(1) Gas permeability According to JIS standard P-8117, the time taken for 200 mL of air to permeate was measured using a Gurley densometer, and the gas permeability (ml / Hr / cm ² / mmAq) was calculated.

(2) Thickness The thickness of the porous electrode base material was measured using a thickness measuring device dial thickness gauge (manufactured by Mitutoyo Corporation, trade name: 7321). The size of the probe was 10 mm in diameter, and the measurement pressure was 1.5 kPa.

(3) Through-direction resistance The electrical resistance (through-direction resistance) in the thickness direction of the porous electrode substrate is 10 mA / cm ² when the porous electrode substrate is sandwiched between gold-plated copper plates and pressed from above and below the copper plate at 1 MPa. The resistance value when a current was passed at a current density of was measured from the following equation.
Through-direction resistance (mΩ · cm ² ) = Measured resistance value (mΩ) × Sample area (cm ² )
(5) Waviness of the porous electrode substrate The undulation of the porous electrode substrate is calculated from the difference between the maximum value and the minimum value when the porous electrode substrate having a length of 250 mm and a width of 250 mm is placed on a flat plate. did.

(6) Power generation characteristics when incorporated in a fuel cell A catalyst layer (catalyst layer area: 25 cm ² , Pt adhesion amount: 0.3 mg / kg) composed of catalyst-supported carbon (catalyst: Pt, catalyst support amount: 50 mass%) on both sides cm ² ) perfluorosulfonic acid polymer electrolyte membrane (film thickness: 30 μm) with two sets of porous electrodes so that the three-dimensional structure side without a three-dimensional entangled structure is in contact with the polymer electrolyte membrane The MEA was obtained by sandwiching the substrates and joining them together. The MEA was sandwiched between two carbon separators having a bellows-like gas flow path to produce a polymer electrolyte fuel cell (single cell). And the power generation characteristic at the time of incorporating in a fuel cell was confirmed by measuring the voltage when hydrogen gas and air were supplied to the single cell made into 80 degreeC through the bubbler of 80 degreeC.

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. Moreover, as carbon fiber precursor short fibers (b1), 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 were prepared.

  A precursor sheet and a porous electrode substrate were obtained by the following operations.

[Preparation of papermaking slurry]
Polyacrylamide (Daiichi Kogyo Seiyaku Co., Ltd., trade name: G9210) was used as a dehydrating modifier, and was added to water as a dispersion medium so as to have a concentration of 0.06 g / L. Next, the carbon short fiber (A) is weighed so that the concentration of the short carbon fiber (A) is 3 g / L, put into a slurry supply tank, and the short carbon fiber (A) is used by using a portable mixer (Satake Chemical Machinery, trade name: A630). Was sufficiently dispersed to obtain a slurry (A). Thereafter, the carbon fiber precursor short fibers (b1) are weighed so as to have a concentration of 2 g / L, put into a slurry supply tank, and carbon short using a portable mixer (Satake Chemical Industries, trade name: A630). The slurry (B) was prepared by sufficiently dispersing the fiber (A) and the carbon fiber precursor short fiber (b1) to obtain a papermaking slurry (C).

[Manufacture of precursor sheets]
Using the adjusted papermaking slurry (C), manually using a standard square sheet machine (manufactured by Kumagai Riki Kogyo Co., Ltd., trade name: No. 2555 standard square sheet machine) in accordance with JIS P-8209 method. Then, paper was made and dried to obtain a precursor sheet having a basis weight of 35 g / m ² . The produced precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1.

[Heat and pressure molding]
Next, both sides of the precursor sheet were sandwiched between papers coated with a silicone-based release agent, and then heat-press molded for 3 minutes under conditions of 180 ° C. and 3 MPa in a batch press apparatus.

[Carbonization treatment]
Thereafter, the precursor sheet was carbonized in a batch carbonization furnace in a nitrogen gas atmosphere at 2000 ° C. for 1 hour to obtain a porous electrode substrate.

  The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 2)
A sheet-like material conveying device composed of a net that continuously rotates by connecting a net drive unit and a plain mesh made of plastic net having a width of 60 cm in a belt shape, a slurry supply unit width of 48 cm and a supply slurry amount of 10 L / min. A papermaking slurry (C) similar to that in Example 1 was supplied onto a plain weave mesh by a metering pump into a sheeting apparatus comprising a papermaking slurry supply apparatus and a vacuum dehydration apparatus disposed at the bottom of the net. The papermaking slurry (C) was supplied after being widened to a predetermined size through a flow box for rectification into a uniform flow. Then, it left still, the part which carries out natural dehydration was passed, and it dehydrated with the pressure reduction dehydrator, and obtained the precursor sheet continuously. The target weight was 35 g / m ² . Further, a pressurized water jet treatment apparatus equipped with three water jet nozzles was disposed downstream of the sheet forming apparatus, and the obtained precursor sheet was loaded on the net of the pressurized water jet treatment apparatus. And the pressurized water flow injection pressure was set to 1 MPa, the precursor sheet was passed through the nozzle 1, the nozzle 2 and the nozzle 3 in this order, and the entanglement process was performed to obtain the entangled precursor sheet. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 3)
The carbon fiber precursor short fibers (b1) were dispersed in water containing no dehydrating regulator so that the fiber concentration was 5 g / L, and the carbon short fibers (A) were sufficiently dispersed using a portable mixer. A slurry (D) in which carbon fiber precursor short fibers (b1) were dispersed was obtained.

  In the same manner as in Example 1, the concentration of the short carbon fibers (A) was adjusted to 5 g / L, and the slurry (C) in which the carbon fiber precursor short fibers (b1) were dispersed in the slurry (A). The slurry (B) is prepared by adding the carbon short fiber (A) and the carbon fiber precursor short fiber (b1) so as to have a ratio of 3: 2, and sufficiently dispersing to obtain the papermaking slurry (C). Except for the above, the fibrillar carbon precursor fiber obtained in the same manner as in Example 2 was obtained simultaneously with the precursor sheet and the porous electrode substrate. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 4)
As the fibrillar carbon precursor fiber (b2), an easily splittable acrylic sea-island composite short fiber (b2-2) composed of an acrylic polymer fibrillated by beating and diacetate (cellulose acetate) (Mitsubishi Rayon Co., Ltd.) Manufactured, trade name: Bonnell MVP-C651, average fiber length: 3 mm).

  Disperse this easy split acrylic sea-island composite short fiber into water containing no dehydrating modifier so that the fiber concentration is 5 g / L, and beat and disaggregate it through a disc refiner (manufactured by Kumagaya Rikyu Kogyo Co., Ltd.). It was processed and it was set as the slurry (D) which disperse | distributed the fibril-like carbon precursor fiber (b2-2).

  In the same manner as in Example 1, the concentration of the short carbon fiber (A) was adjusted to 5 g / L, and a slurry (D) in which the fibrillar carbon precursor fiber (b2-2) was dispersed in the slurry (A) (D) ) Is added such that the short carbon fibers (A) and the fibrillar carbon precursor fibers (b2-2) are in a ratio of 3: 2, and the slurry is sufficiently dispersed to prepare a slurry (B). Except for obtaining C), the fibrillar carbon precursor fibers obtained in the same manner as in Example 2 were obtained simultaneously with the precursor sheet and the porous electrode substrate. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 5)
Except that the dehydrating regulator similar to claim 1 was added to the slurry (D) in which the fibrillar carbon precursor fiber (b2-2) of Example 4 was dispersed to a concentration of 0.06 g / L. Obtained a precursor sheet and a porous electrode substrate in the same manner as in Example 4. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 6)
The carbon fiber precursor short fiber (b1) is added to the slurry in which the fibrillated carbon precursor fiber (b2-2) of Example 4 is dispersed, and the carbon fiber precursor short fiber (b1) and the fibrillar carbon precursor fiber ( A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 5 except that the slurry (D) adjusted so that the fiber ratio of b2-2) was 1: 1 was obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 7)
In the slurry (D) composed of the carbon fiber precursor short fibers (b1) and the fibrillar carbon precursor fibers (b2-2) of Example 6, the concentration of the dehydrating modifier in the papermaking slurry (C) is 0. It is added with water as a dispersion medium so as to be 06 g / L, and the fiber concentration of the carbon fiber precursor short fiber (b1) and the fibrillar carbon precursor fiber (b2-2) is adjusted to 0.5 g / L. Then, a slurry (B-1) in which the concentration of the carbon short fiber (A) and the carbon fiber precursor short fiber (b1) and the fibrillar carbon precursor fiber (b2-2) is 1.0 g / L is used as a papermaking slurry. A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 6 except that it was used as (C). The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 8)
Water as a dispersion medium is added to the same slurry (B) as that of Example 2 adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) is 0.06 g / L, and the slurry (B- 1) A precursor sheet subjected to the entanglement treatment was obtained in the same manner as in Example 2 except that the concentration of the short carbon fiber (A) and the short carbon fiber precursor fiber (b1) was 1.5 g / L. . This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

Example 9
Water as a dispersion medium is added to the same slurry (B) as in Example 4 adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) is 0.06 g / L, and the slurry (B -1) A precursor sheet that was entangled in the same manner as in Example 2 except that the concentration of the short carbon fiber (A) and the fibrillar carbon precursor fiber (b2-2) was 1.5 g / L. Obtained. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 10)
Water as a dispersion medium was added to the same slurry (B) as in Example 5 adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) was 0.06 g / L, and the slurry (b- 1) A precursor sheet that was entangled in the same manner as in Example 2 except that the concentration of the short carbon fiber (A) and the fibrillar carbon precursor fiber (b2-2) was 1.5 g / L. Obtained. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 11)
Using the same slurry (B) as in Example 2 adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) was 0.06 g / L, the amount of slurry supplied was 9 L / min, and The slurry (B) is continuously added with water as a dispersion medium so that the concentration of the short carbon fibers (A) and the short carbon fiber precursor fibers (b1) in the slurry (B-1) is 1.5 g / L. A precursor sheet was obtained which was diluted and entangled in the same manner as in Example 2 except that the amount of the papermaking slurry (C) supplied to the flow box was 30 L / min. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 12)
Using the same slurry (B) as in Example 4 adjusted so that the concentration of the dehydrating modifier in the papermaking slurry (C) was 0.06 g / L, the supply slurry amount was 9 L / min, and The slurry (B) is continuously added with water as a dispersion medium so that the concentration of the short carbon fibers (A) and the fibrillar carbon precursor fibers (b2-2) in the slurry (B-1) is 1.5 g / L. The precursor sheet subjected to the entanglement treatment was obtained in the same manner as in Example 2 except that the amount of the papermaking slurry (C) supplied to the flow box was 30 L / min. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 13)
Using the same slurry (B) as in Example 5 adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) was 0.06 g / L, the amount of slurry supplied was 9 L / min, and The slurry (B) is continuously added with water as a dispersion medium so that the concentration of the short carbon fibers (A) and the fibrillar carbon precursor fibers (b2-2) in the slurry (B-1) is 1.5 g / L. The precursor sheet subjected to the entanglement treatment was obtained in the same manner as in Example 2 except that the amount of the papermaking slurry (C) supplied to the flow box was 30 L / min. This entangled precursor sheet had few fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 1 or less. Furthermore, this precursor sheet subjected to the entanglement treatment was subjected to a heat and pressure molding treatment and a carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 14)
Slurry (A) comprising short carbon fibers (A) similar to Example 4 and a fibrillar carbon precursor adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) is 0.06 g / L. Using the slurry (D) composed of body fibers (b2-2), the precursor sheet and the same as in Example 11 except that the amount of each supplied slurry was 5.4 L / min and 3.6 L / min. A porous electrode substrate was obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 15)
Slurry (A) comprising carbon short fibers (A) similar to Example 6 and carbon fiber precursor adjusted so that the concentration of the dehydrating regulator in the papermaking slurry (C) is 0.06 g / L. A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 14 except that the slurry (D) composed of the short fibers (b1) and the fibrillar carbon precursor fibers (b2-2) was used. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 16)
Dispersed in the slurry (D) comprising the fibrillar carbon precursor fiber (b2-2) of Example 4 adjusted so that the concentration of the dehydrating modifier in the papermaking slurry (C) was 0.06 g / L. Example 4 except that water as a medium was added and the concentrations of the short carbon fibers (A) and the fibrillar carbon precursor fibers (b2-2) in the papermaking slurry (C) were 1.0 g / L. In the same manner as above, a precursor sheet and a porous electrode substrate were obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 17)
After adding a dehydrating modifier to the slurry (D) composed of the fibrillar carbon precursor fiber (b2-2) of Example 5 so that the concentration in the papermaking slurry (C) is 0.06 g / L. , Except that water as a dispersion medium was added and the concentration of the short carbon fiber (A) and the fibrillar carbon precursor fiber (b2-2) in the papermaking slurry (C) was 1.0 g / L. A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 5. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and each fiber bundle ratio was one. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Examples 18 to 19)
A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 11 except that the concentration of the dehydrating modifier in the papermaking slurry (C) was changed to the conditions shown in Table 1. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 2 or less. Furthermore, the obtained porous electrode base material had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 2 or less, respectively. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Examples 20 to 21)
The concentration of the short carbon fiber (A) and the short carbon fiber precursor fiber (b1) in the slurry (A), the slurry (B), and the papermaking slurry (C) is the conditions shown in Tables 1 and 2, and the amount of slurry supplied is A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 2 except for the change. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 2 or less. Furthermore, the obtained porous electrode base material had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 2 or less, respectively. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Examples 22 to 23)
Example 11 except that the amount of the supply slurry was changed, and the concentrations of the short carbon fiber (A) and the short carbon fiber precursor fiber (b1) in the papermaking slurry (C) were set to the conditions shown in Tables 1 and 2. Similarly, a precursor sheet and a porous electrode substrate were obtained. The precursor sheet had few fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1 or less. Furthermore, the obtained porous electrode base material had almost no fiber bundles in which short carbon fibers were converged, and each fiber bundle ratio was 1 or less. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Examples 24-28)
Tables 1 and 2 show the mass ratio of the short carbon fiber (A), the short carbon fiber precursor fiber (b1), and the fibrillar carbon precursor fiber (b2) in the slurry (B-1) and the concentration of the dehydrating modifier. A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 15 except that the conditions shown in FIG. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 2 or less. Furthermore, the obtained porous electrode base material had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was 2 or less, respectively. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 29)
Precursor in the same manner as in Example 15 except that polyacrylonitrile pulp (b2-1) in which a large number of fibrils having a diameter of 3 μm or less were branched from the fibrous trunk was used as the fibrillar carbon precursor fiber (b2). Sheets and porous electrode substrates were obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.
(Example 30)
Porous in the same manner as in Example 15 except that the precursor sheet subjected to pressure and heat molding was oxidized in the atmosphere at 280 ° C. for 1 minute before the carbonization treatment step of the entangled precursor sheet in Example 15. A quality electrode substrate was obtained. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 31)
100 parts by mass of the precursor sheet of Example 1 was impregnated with a water-dispersed phenol resin (trade name: PR-55464, manufactured by Sumitomo Bakelite Co., Ltd.) and sufficiently dried at room temperature, and the nonvolatile content of the phenol resin was 60 masses. A phenol resin-impregnated sheet with partial adhesion was obtained. Further, the precursor sheet impregnated with this phenolic resin was subjected to heat and pressure molding treatment and carbonization treatment in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness, and handling properties were also good. It was. The evaluation results are shown in Table 2.

(Example 32)
A phenol resin-impregnated sheet and a porous electrode substrate were obtained in the same manner as in Example 31 except that the entangled precursor sheet of Example 15 was used. The obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. In addition, there was almost no in-plane shrinkage during carbonization treatment, the swell was as small as 2 mm or less, and the surface smoothness was good. It was. The evaluation results are shown in Table 2.

(Example 33)
[Manufacture of membrane-electrode assembly (MEA)]
Two sets of the porous electrode substrates obtained in Example 15 were prepared as the cathode and anode porous carbon electrode substrates. Further, a catalyst layer (catalyst layer area: 25 cm ² , Pt) composed of catalyst-supported carbon (catalyst: Pt, catalyst support amount: 50 mass%) on both surfaces of a perfluorosulfonic acid polymer electrolyte membrane (film thickness: 30 μm). A laminate having an adhesion amount of 0.3 mg / cm ² ) was prepared. And this laminated body was pinched | interposed with the porous carbon electrode base material for cathodes and anodes, these were joined, and MEA was obtained.

[Evaluation of fuel cell characteristics of MEA]
The obtained MEA was sandwiched between two carbon separators having bellows-like gas flow paths to form a polymer electrolyte fuel cell (single cell).

The fuel cell characteristics were evaluated by measuring the current density-voltage characteristics of this single cell. Hydrogen gas was used as the fuel gas, and air was used as the oxidizing gas. The temperature of the single cell was 80 ° C., the fuel gas utilization rate was 60%, and the oxidizing gas utilization rate was 40%. Further, the humidification of the fuel gas and the oxidizing gas was performed by passing the fuel gas and the oxidizing gas through an 80 ° C. bubbler, respectively. As a result, when the current density was 0.8 A / cm ² , the cell voltage of the fuel cell was 0.68 V, the internal resistance of the cell was 2.3 mΩ, and good characteristics were exhibited.

(Comparative Example 1)
A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that the concentration of the dehydrating modifier was changed to the conditions shown in Table 2. In the precursor sheet, a bundle of short carbon fibers was observed, and the fiber bundle ratio was 0. However, it was difficult to sufficiently dehydrate water as a dispersion medium from the slurry, and the dehydration position was not constant. Compared with Example 3, sheet formation deteriorated. Further, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was zero. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, penetration direction resistance and handling properties were also good, but it originated from the formation deterioration of the precursor sheet It was confirmed that there were thick spots and gas permeability spots. The evaluation results are shown in Table 2.

(Comparative Example 2)
A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that the concentration of the dehydrating modifier was changed to the conditions shown in Table 2. In the precursor sheet, fiber bundles in which short carbon fibers were bundled were observed, and the fiber bundle ratio was four. Furthermore, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 4. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. The evaluation results are shown in Table 2.

(Comparative Example 3)
A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that the fiber concentrations in the slurry (A) and the slurry (B) were changed to the conditions shown in Tables 1 and 2. In the precursor sheet, fiber bundles in which short carbon fibers were bundled were observed, and the fiber bundle ratio was 5. Furthermore, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 5. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. The evaluation results are shown in Table 2.

(Comparative Example 4)
A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that the fiber concentrations in the slurry (A) and the slurry (B) were changed to the conditions shown in Tables 1 and 2. In the precursor sheet, a bundle of short carbon fibers was observed, and the fiber bundle ratio was 1. However, it was necessary to prepare a large amount of slurry for papermaking, and because a large slurry tank was used, Example 3 was used. Compared with the manufacturing cost increased. Furthermore, in the obtained porous electrode substrate, a fiber bundle in which short carbon fibers were converged was observed, and the fiber bundle ratio was 1. There was almost no in-plane shrinkage during carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, penetration direction resistance, thickness spots and handling properties were also good. Costs also increased. The evaluation results are shown in Table 2.

(Comparative Example 5)
The same procedure as in Example 3 was conducted except that the concentration of the short carbon fiber (A) and the short carbon fiber precursor fiber (b1) in the papermaking slurry (C) was changed to the conditions shown in Table 2 by changing the amount of the supplied slurry. Thus, a precursor sheet and a porous electrode substrate were obtained. In the precursor sheet, fiber bundles in which short carbon fibers were bundled were observed, and the fiber bundle ratio was 3. Further, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 3. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. The evaluation results are shown in Table 2.

(Comparative Example 6)
The same procedure as in Example 3 was conducted except that the concentration of the short carbon fiber (A) and the short carbon fiber precursor fiber (b1) in the papermaking slurry (C) was changed to the conditions shown in Table 2 by changing the amount of the supplied slurry. Thus, a precursor sheet and a porous electrode substrate were obtained. The precursor sheet had few fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 0. However, when adjusting the slurry for papermaking, a large amount of dilution water was required to obtain a predetermined concentration. The manufacturing cost for the conversion has increased. Moreover, the obtained porous electrode base material had almost no fiber bundles in which short carbon fibers were converged, and the fiber bundle ratio was zero. There was almost no in-plane shrinkage during the carbonization treatment, the swell was as small as 2 mm or less, the surface smoothness was good, and the gas permeability, thickness, penetration direction resistance, thickness unevenness and handling property were also good respectively. Since the production cost of the precursor sheet was high, the production cost of the obtained porous electrode substrate was also higher than that in Example 3. The evaluation results are shown in Table 2.

(Comparative Example 7)
Except that the mass ratio of the short carbon fiber (A), the short carbon fiber precursor fiber (b1) and the fibrillar carbon precursor fiber (b2) in the slurry (B) was the conditions shown in Tables 1 and 2, In the same manner as in Example 6, a precursor sheet and a porous electrode substrate were obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1 or less. Furthermore, the obtained porous electrode substrate had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 1. Moreover, the in-plane shrinkage | contraction at the time of carbonization process and the wave | undulation compared with Example 3 also became large with 3 mm. Gas permeability, thickness, penetration direction resistance, and thickness spots were good, but handling properties were worse than in Example 3.

(Comparative Example 8)
Except that the mass ratio of the short carbon fiber (A), the short carbon fiber precursor fiber (b1) and the fibrillar carbon precursor fiber (b2) in the slurry (B) was the conditions shown in Tables 1 and 2, In the same manner as in Example 6, a precursor sheet and a porous electrode substrate were obtained. The precursor sheet had almost no fiber bundles in which short carbon fibers were bundled, and the fiber bundle ratio was 3 or less. Further, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 3. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. Further, the handling property was deteriorated as compared with Example 3. The evaluation results are shown in Table 2.

(Comparative Example 9)
After adding short carbon fibers (A) to water that does not contain polyacrylamide (Daiichi Kogyo Seiyaku Co., Ltd., trade name: G9210) as a dehydrating modifier, and thoroughly dispersing using a portable mixer, dehydrating A precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that the modifier was added. In the precursor sheet, fiber bundles in which short carbon fibers were bundled were observed, and the fiber bundle ratio was four. Furthermore, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 4. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. The evaluation results are shown in Table 2.

(Comparative Example 10)
Carbon fiber precursor short fibers (b1) were added to water not containing a dehydrating modifier, and after sufficiently dispersing using a portable mixer, carbon short fibers (A) were added, and further sufficiently dispersed using a portable mixer. Thereafter, a precursor sheet and a porous electrode substrate were obtained in the same manner as in Example 3 except that a dehydrating modifier was added. In the precursor sheet, fiber bundles in which short carbon fibers were bundled were observed, and the fiber bundle ratio was four. Furthermore, in the obtained porous electrode substrate, fiber bundles in which short carbon fibers were converged were observed, and the fiber bundle ratio was 4. There was almost no in-plane shrinkage at the time of carbonization treatment, waviness was as small as 2 mm or less, surface smoothness was good, thickness, penetration direction resistance, and handling properties were also good, but the part where the fiber bundle was observed It was observed that the gas permeability was lower than that of the other portions, and it was confirmed that the gas permeability spots were present. The evaluation results are shown in Table 2.

Claims (17)

The following (I) to (IV) are performed in a method for producing a porous electrode substrate precursor sheet by paper-making a fiber mixed slurry comprising a mixture containing short carbon fibers (A) and precursor fibers (b). A method for producing a porous electrode substrate precursor sheet.
(I) A dehydrating modifier is mixed with the dispersion medium (A) to obtain a dispersing medium (B) containing the dehydrating modifier.
(II) The dispersion medium (B) obtained in the above (I) and the short carbon fiber (A) are mixed to obtain a slurry (A).
(III) The slurry (A) obtained in (II) and the precursor fiber (b) are mixed to obtain a slurry (B).
(IV) A porous electrode base material comprising a paper mixture of the slurry (B) obtained in (III) as a papermaking slurry (C) and comprising a fiber mixture of carbon short fibers (A) and precursor fibers (b) A precursor sheet is obtained.
In the above (I) to (IV), the following conditions are satisfied.
In the above (I), the amount of the dehydrating regulator is 0.01 to 0.1 g / L per 1 L of the papermaking slurry (C) dispersion medium.
In said (II), the quantity of a short carbon fiber (A) is an quantity used as 1-10g per 1L of dispersion media of a slurry (A).
In the above (III), the amount of the precursor fiber (b) is an amount satisfying the following formula 1 by mass ratio.
(Formula 1)
0.1 ≦ precursor fiber (b) / (precursor fiber (b) + carbon short fiber (A)) ≦ 0.6   In the mixing of the slurry (A) and the precursor fiber (b) in (III), the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating modifier are mixed to obtain a slurry (D). The manufacturing method according to claim 1, wherein the slurry (D) is mixed with the slurry (A) obtained in (II).   The method according to claim 2, wherein after obtaining the slurry (D), a dehydrating regulator is added to the slurry (D) and then mixed with the slurry (A) obtained in (II).   To the slurry (D), a dehydrating modifier diluted with the dispersion medium (A-2) is added, and then mixed with the slurry (A) obtained in (II), and 0.8 to 1.. The slurry (B-1) in which 8 g of the fiber substance is mixed is obtained, and the slurry (B-1) is changed to the slurry (B) in (IV) to make the slurry (B-1) as the papermaking slurry (C). Manufacturing method.   In the mixing of the slurry (A) and the precursor fiber (b) in (III), the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating modifier are mixed to obtain a slurry (D). The slurry (D) is mixed with the slurry (A) obtained in (II) and the dispersion medium (A-3), and a slurry in which 0.8 to 1.8 g of fiber material is mixed per liter of the dispersion medium ( The production method according to claim 1, wherein the paper (B-1) is obtained and the slurry (B-1) is changed to the slurry (B) in (IV) to make the paper (S-1) as the papermaking slurry (C).   The slurry (D) is obtained, and then a dehydrating modifier is added to the slurry (D) and then mixed with the slurry (A) and the dispersion medium (A-3) obtained in (II). The manufacturing method as described.   In the above (III), the slurry (B) is diluted with the dispersion medium (A-3) to obtain a slurry (B-1) in which 0.8 to 1.8 g of a fiber substance is mixed per liter of the dispersion medium. The manufacturing method according to any one of claims 1 to 3, wherein in (IV), the slurry (B-1) is used as the papermaking slurry (C) instead of the slurry (B).   In the mixing of the slurry (A) and the precursor fiber (b) in (III), the dispersion medium (A-1) and the precursor fiber (b) containing no dehydrating modifier are mixed to form a slurry (D-1 The slurry (D-1) is mixed with the slurry (A) obtained in (II), and a slurry (B-1) in which 0.8 to 1.8 g of fiber material is mixed per liter of the dispersion medium. And the slurry (B-1) is changed to the slurry (B) in (IV) to make the paper (S-1) as the papermaking slurry (C).   The method according to claim 8, wherein after obtaining the slurry (D-1), a dehydrating regulator is added to the slurry (D-1), and then the slurry (A) obtained in (II) is mixed. .   The porous electrode substrate precursor sheet obtained in any one of claims 1 to 9 is heated and pressurized, and the heated and pressurized porous electrode substrate precursor sheet is carbonized at a temperature of 1000 ° C or higher. For producing a porous electrode substrate.   The manufacturing method of Claim 10 which oxidizes the heat-pressed porous electrode base material precursor sheet | seat between heat press treatment and carbonization treatment.   The manufacturing method according to any one of claims 10 and 11, wherein the porous electrode substrate precursor sheet obtained by the manufacturing method according to claims 1 to 9 is entangled before the heat and pressure treatment.   The production method according to claim 10 or 11, wherein the porous electrode substrate precursor sheet is impregnated with a carbonizable resin (c) before the heat and pressure treatment.   The production method according to claim 12, wherein the porous electrode substrate precursor sheet is impregnated with the carbonizable resin (c) between the entanglement treatment and the heat and pressure treatment.   The porous electrode base material obtained by the method in any one of Claims 10-14.   A membrane-electrode assembly using the porous electrode substrate according to claim 15.   A polymer electrolyte fuel cell using the membrane-electrode assembly according to claim 16.