JP3808478B2 - Molding material for fuel cell separator - Google Patents
Molding material for fuel cell separator Download PDFInfo
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- JP3808478B2 JP3808478B2 JP2004134013A JP2004134013A JP3808478B2 JP 3808478 B2 JP3808478 B2 JP 3808478B2 JP 2004134013 A JP2004134013 A JP 2004134013A JP 2004134013 A JP2004134013 A JP 2004134013A JP 3808478 B2 JP3808478 B2 JP 3808478B2
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- 239000012778 molding material Substances 0.000 title claims description 73
- 239000000446 fuel Substances 0.000 title claims description 43
- 239000003795 chemical substances by application Substances 0.000 claims description 61
- 239000003822 epoxy resin Substances 0.000 claims description 49
- 229920000647 polyepoxide Polymers 0.000 claims description 49
- 239000000843 powder Substances 0.000 claims description 40
- 239000002245 particle Substances 0.000 claims description 38
- 239000003575 carbonaceous material Substances 0.000 claims description 36
- 229920005989 resin Polymers 0.000 claims description 20
- 239000011347 resin Substances 0.000 claims description 20
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 13
- 239000000945 filler Substances 0.000 claims description 11
- -1 biphenyl ester Chemical class 0.000 claims description 10
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 claims description 10
- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 7
- 239000005011 phenolic resin Substances 0.000 claims description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 6
- 229910044991 metal oxide Inorganic materials 0.000 claims description 6
- 150000004706 metal oxides Chemical class 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 150000004696 coordination complex Chemical class 0.000 claims description 5
- 239000012255 powdered metal Substances 0.000 claims description 5
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 4
- 239000004305 biphenyl Substances 0.000 claims description 4
- 239000011365 complex material Substances 0.000 claims description 4
- NYGZLYXAPMMJTE-UHFFFAOYSA-M metanil yellow Chemical group [Na+].[O-]S(=O)(=O)C1=CC=CC(N=NC=2C=CC(NC=3C=CC=CC=3)=CC=2)=C1 NYGZLYXAPMMJTE-UHFFFAOYSA-M 0.000 claims description 4
- 239000006230 acetylene black Substances 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 3
- 239000005995 Aluminium silicate Substances 0.000 claims description 2
- 229930185605 Bisphenol Natural products 0.000 claims description 2
- 150000008065 acid anhydrides Chemical class 0.000 claims description 2
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- 235000012211 aluminium silicate Nutrition 0.000 claims description 2
- 150000001412 amines Chemical class 0.000 claims description 2
- 229910021383 artificial graphite Inorganic materials 0.000 claims description 2
- 239000000440 bentonite Substances 0.000 claims description 2
- 229910000278 bentonite Inorganic materials 0.000 claims description 2
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 claims description 2
- 235000010290 biphenyl Nutrition 0.000 claims description 2
- 239000006229 carbon black Substances 0.000 claims description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 2
- 239000000395 magnesium oxide Substances 0.000 claims description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 2
- 239000010445 mica Substances 0.000 claims description 2
- 229910052618 mica group Inorganic materials 0.000 claims description 2
- 229910021382 natural graphite Inorganic materials 0.000 claims description 2
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N phenylbenzene Natural products C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 claims description 2
- 229920006122 polyamide resin Polymers 0.000 claims description 2
- 239000000463 material Substances 0.000 description 27
- 238000000465 moulding Methods 0.000 description 14
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 12
- 239000005518 polymer electrolyte Substances 0.000 description 12
- 238000005452 bending Methods 0.000 description 9
- 239000007789 gas Substances 0.000 description 9
- 229910002804 graphite Inorganic materials 0.000 description 8
- 239000010439 graphite Substances 0.000 description 8
- 238000000034 method Methods 0.000 description 8
- 239000000975 dye Substances 0.000 description 6
- YGSDEFSMJLZEOE-UHFFFAOYSA-N Salicylic acid Natural products OC(=O)C1=CC=CC=C1O YGSDEFSMJLZEOE-UHFFFAOYSA-N 0.000 description 5
- 238000006243 chemical reaction Methods 0.000 description 5
- 239000001257 hydrogen Substances 0.000 description 5
- 229910052739 hydrogen Inorganic materials 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 229920003986 novolac Polymers 0.000 description 5
- 238000010298 pulverizing process Methods 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- 229920000557 Nafion® Polymers 0.000 description 4
- PXKLMJQFEQBVLD-UHFFFAOYSA-N bisphenol F Chemical compound C1=CC(O)=CC=C1CC1=CC=C(O)C=C1 PXKLMJQFEQBVLD-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000003792 electrolyte Substances 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- FJKROLUGYXJWQN-UHFFFAOYSA-N papa-hydroxy-benzoic acid Natural products OC(=O)C1=CC=C(O)C=C1 FJKROLUGYXJWQN-UHFFFAOYSA-N 0.000 description 4
- 229960004889 salicylic acid Drugs 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 3
- 229910001882 dioxygen Inorganic materials 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 150000003242 quaternary ammonium salts Chemical class 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 238000003411 electrode reaction Methods 0.000 description 2
- 239000002737 fuel gas Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 230000001737 promoting effect Effects 0.000 description 2
- XGRZWVWRMKAQNU-UHFFFAOYSA-K 2-carboxyphenolate;chromium(3+) Chemical compound [Cr+3].OC1=CC=CC=C1C([O-])=O.OC1=CC=CC=C1C([O-])=O.OC1=CC=CC=C1C([O-])=O XGRZWVWRMKAQNU-UHFFFAOYSA-K 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 239000000987 azo dye Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000007580 dry-mixing Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000003487 electrochemical reaction Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000007770 graphite material Substances 0.000 description 1
- 238000005087 graphitization Methods 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 150000004698 iron complex Chemical class 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
Landscapes
- Fuel Cell (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Description
本発明は、燃料電池のセパレータ用成形材料に関する。より具体的には、例えば、高分子電解質型燃料電池やダイレクトメタノール型燃料電池などに用いることができ、かつ、伝導性炭素材料、エポキシ樹脂及び硬化剤などを含むセパレータ(separator)に関する。 The present invention relates to a molding material for a separator of a fuel cell. More specifically, the present invention relates to a separator that can be used in, for example, a polymer electrolyte fuel cell, a direct methanol fuel cell, and the like and includes a conductive carbon material, an epoxy resin, a curing agent, and the like.
燃料電池は、アノードには水素含有燃料ガスを、カソードには酸素含有酸化性ガスをそれぞれ供給して水素と酸素との電気化学反応によって電気エネルギーを得る装置である。燃料電池は、ＮＯｘガスや煤煙などを排出せず、騒音や振動なども少ない親環境的な装置であるため、次世代エネルギー源として多くの研究が行われている。特に、排気ガスを放出しない特性から、自動車などの移動体の駆動エネルギー源として使用するための開発が行われており、その実用化を目前に控えている。 A fuel cell is a device that obtains electrical energy by an electrochemical reaction between hydrogen and oxygen by supplying a hydrogen-containing fuel gas to an anode and an oxygen-containing oxidizing gas to a cathode. A fuel cell is an environmentally friendly device that does not emit NOx gas, smoke, etc., and has little noise and vibration. Therefore, much research has been conducted as a next-generation energy source. In particular, since it does not emit exhaust gas, it has been developed for use as a driving energy source for a moving body such as an automobile, and its practical use is about to be put forward.
このような燃料電池は、使用される電解質の種類によってアルカリ型、燐酸型、溶融炭酸塩型、固体酸化物型及び高分子電解質型燃料電池に分類することができる。特に、移動体の駆動エネルギー源としては、高分子電解質型燃料電池(ＰＥＭＦＣ：Polymer Electrolyte Membrane Fuel Cell、単にＰＥＦＣともいう)やダイレクトメタノール型燃料電池(ＤＭＦＣ：Direct Methanol Fuel Cell)が最適であると考えられている。 Such fuel cells can be classified into alkaline type, phosphoric acid type, molten carbonate type, solid oxide type and polymer electrolyte type fuel cells according to the type of electrolyte used. In particular, a polymer electrolyte fuel cell (PEMFC) or direct methanol fuel cell (DMFC) is optimal as a driving energy source for a moving body. It is considered.
高分子電解質型燃料電池は高分子を電解質として用いているため、電解質による腐食や電解質の蒸発のおそれがない。また、単位面積当たりの電流密度を大きくすることができるため、他の燃料電池に比べて出力特性に優れている。その他、作動温度が相対的に低いなどの利点を有している。 Since the polymer electrolyte fuel cell uses a polymer as an electrolyte, there is no risk of corrosion due to the electrolyte or evaporation of the electrolyte. In addition, since the current density per unit area can be increased, the output characteristics are superior to those of other fuel cells. In addition, there are advantages such as a relatively low operating temperature.
高分子電解質型燃料電池について具体例を説明する。高分子電解質型燃料電池の単位電池は、例えば、高分子電解質（例えば、デュポン社製ナフィオン（Ｒ)）溶液の乾燥層を中心として、その両面にナフィオンシートと、電極として白金／炭素触媒層と、テフロン（Ｒ）（ポリテトラフルオロエチレン）処理したカーボンクロスと、セパレータと、金属からなるエンドプレートとが一連の順序で積層された構造を有している。 A specific example of the polymer electrolyte fuel cell will be described. A unit cell of a polymer electrolyte fuel cell includes, for example, a dry layer of a polymer electrolyte (for example, Nafion (R) solution manufactured by DuPont), a Nafion sheet on both sides, and a platinum / carbon catalyst layer as an electrode. , A carbon cloth treated with Teflon (R) (polytetrafluoroethylene), a separator, and an end plate made of metal are laminated in a series of order.
ここで、一方のセパレータのガス流路チャネルを介して供給される燃料ガスとしての水素ガスは、アノードの白金／炭素触媒と反応しながら電子を奪われて水素イオンになる。発生した水素イオンは高分子電解質膜であるナフィオンシートおよびナフィオン溶液乾燥層を通過して反対側のカソードに移動する。一方で、他方のセパレータのガス流路チャネルを介して供給される酸素ガスは、外部回路を介してカソードに移動してきた電子によって還元され、酸素イオンとなる。ここで、高分子電解質膜を透過してカソードに移動してきた前記水素イオンと反応してカソードの表面に水が生成される。生成した水は、未反応の酸素ガスと共にガス流路チャネルの出口に排出される。 Here, the hydrogen gas as the fuel gas supplied through the gas flow channel of one separator is deprived of electrons while reacting with the platinum / carbon catalyst of the anode and becomes hydrogen ions. The generated hydrogen ions pass through the Nafion sheet and the Nafion solution dry layer, which are polymer electrolyte membranes, and move to the cathode on the opposite side. On the other hand, the oxygen gas supplied via the gas flow channel of the other separator is reduced by the electrons that have moved to the cathode via the external circuit and become oxygen ions. Here, water reacts with the hydrogen ions that have passed through the polymer electrolyte membrane and moved to the cathode, and water is generated on the surface of the cathode. The generated water is discharged together with unreacted oxygen gas to the outlet of the gas flow channel.
このとき、アノードにおける触媒反応で発生した電子が外部回路に沿って流れることによって、電力を得ることができる。 At this time, electric power can be obtained by the electrons generated by the catalytic reaction at the anode flowing along the external circuit.
従って、高分子電解質型燃料電池のセパレータは、水素ガスおよび酸素ガスを完全に分離した状態で電極に供給するために、非常に高いガス不透過性が要求される。また、電極反応で生じた熱を効率よく除去するために熱伝導性が高くなければならない。さらに、電極反応によって生じた電気エネルギーを集電体であるエンドプレートへ損失を最小限にして伝達するために、電気伝導性が高いことも必要である。また、移動体用の燃料電池として用いられる場合、移動中に必然的に発生する各種振動に耐えられる程度の耐久性（例えば、剛性）を有していなければならない。 Therefore, the separator of the polymer electrolyte fuel cell is required to have a very high gas impermeability in order to supply hydrogen gas and oxygen gas to the electrode in a completely separated state. Moreover, in order to efficiently remove the heat generated by the electrode reaction, the thermal conductivity must be high. Furthermore, in order to transmit the electric energy generated by the electrode reaction to the end plate, which is a current collector, with a minimum loss, it is also necessary to have high electrical conductivity. Further, when used as a fuel cell for a moving body, it must have durability (for example, rigidity) enough to withstand various vibrations that inevitably occur during movement.
このようなセパレータを製作するための材料と方法として、黒鉛粉末７０ｗｔ％〜８５ｗｔ％に、熱硬化性樹脂１０ｗｔ％〜２５ｗｔ％と、平均粒径が前記黒鉛粉末の１／２０以下の球状シリカ１ｗｔ％〜３ｗｔ％などとを均一に混合し、厚さ０.５ｍｍ〜５.０ｍｍに成形する技術が特許文献１に開示されている。しかしながら実際には、黒鉛、球状シリカ、微粉砕した熱硬化性樹脂、離型剤などの各粉末材料が有する帯電分布度が互いに異なり、かつ、ばらつきを有しているために、上記各材料を均一に混合することが困難である。このため、成形されたセパレータの特性は、全体にわたって一定ではなく、部分によって変化する可能性がある。 As a material and method for manufacturing such a separator, 1 wt% of spherical silica having an average particle size of 1/20 or less of the graphite powder and 70 wt% to 85 wt% of the graphite powder, 10 wt% to 25 wt% of the thermosetting resin. Patent Document 1 discloses a technique for uniformly mixing with 3% to 3% by weight or the like and forming the film to a thickness of 0.5 mm to 5.0 mm. In practice, however, the charge distributions of the powder materials such as graphite, spherical silica, finely pulverized thermosetting resin, and release agent are different from each other and have variations. It is difficult to mix uniformly. For this reason, the characteristics of the molded separator are not constant throughout and may vary from part to part.
即ち、高分子電解質型燃料電池やダイレクトメタノール型燃料電池に用いるセパレータの成形材料として、導電性炭素材料に、熱硬化性樹脂あるいは熱可塑性樹脂、硬化剤、各種フィラーあるいは繊維状物質を混合した材料が幅広く提案されているが、各粉末材料の帯電分布度が互いに異なるという課題を解決することが求められている。 That is, as a molding material for a separator used in a polymer electrolyte fuel cell or a direct methanol fuel cell, a material obtained by mixing a conductive carbon material with a thermosetting resin or thermoplastic resin, a curing agent, various fillers, or a fibrous substance. However, it is required to solve the problem that the charge distributions of the powder materials are different from each other.
また、特許文献２には、熱硬化性樹脂として、浸透処理を施した黒鉛材料が開示されているが、黒鉛化及び樹脂含浸処理によって成形加工比が増加するという問題点がある。
本発明は、上述したような、従来のセパレータ用成形材料の諸般問題点を解決するために創案されたものである。本発明は、導電性炭素材料、エポキシ樹脂、硬化剤などを適切な粒径に粉砕して帯電制御剤と混合することによって、各粉末の均一な混合を可能にし、混合粉末の成形性を向上させ、最終成形後に適切な導電性と機械的強度が実現可能である燃料電池セパレータ用成形材料を提供することを目的とする。 The present invention has been devised to solve the various problems of the conventional molding materials for separators as described above. The present invention makes it possible to uniformly mix each powder by crushing a conductive carbon material, epoxy resin, curing agent, etc. to an appropriate particle size and mixing with a charge control agent, thereby improving the moldability of the mixed powder. It is an object of the present invention to provide a molding material for a fuel cell separator capable of realizing appropriate electrical conductivity and mechanical strength after final molding.
本発明のセパレータ用成形材料は、導電性炭素材料６５重量部〜１００重量部と、エポキシ樹脂５重量部〜３５重量部と、前記エポキシ樹脂１００重量部に対する硬化剤５重量部〜７０重量部と、前記炭素材料、前記エポキシ樹脂及び前記硬化剤の混合量１００重量部に対する帯電制御剤０.１重量部〜５重量部とを含んでいる。 The separator molding material of the present invention includes conductive carbon material 65 parts by weight to 100 parts by weight, epoxy resin 5 parts by weight to 35 parts by weight, and curing agent 5 parts by weight to 70 parts by weight with respect to 100 parts by weight of the epoxy resin. , 0.1 to 5 parts by weight of a charge control agent with respect to 100 parts by weight of the mixture of the carbon material, the epoxy resin and the curing agent.
本発明によれば、帯電制御剤を含有することによって、導電性炭素材料、エポキシ樹脂、硬化剤などの各粉末が非常に均一に分散・混合できるため、安息角が小さく、成形性に優れ、最終成形後に適切な導電性と機械的強度が実現可能である燃料電池セパレータ用成形材料を提供することができる。 According to the present invention, by containing a charge control agent, each powder of conductive carbon material, epoxy resin, curing agent and the like can be dispersed and mixed very uniformly, so the angle of repose is small, and the moldability is excellent. It is possible to provide a molding material for a fuel cell separator that can achieve appropriate electrical conductivity and mechanical strength after final molding.
本発明の燃料電池セパレータ用成形材料（以下、単に「成形材料」ともいう）は、導電性炭素材料６５重量部〜１００重量部と、エポキシ樹脂５重量部〜３５重量部と、エポキシ樹脂１００重量部に対して硬化剤５重量部〜７０重量部と、前記炭素材料、エポキシ樹脂及び硬化剤の混合量１００重量部に対する帯電制御剤０.１重量部〜５重量部とを含んでいる。ここで、上述の各材料は粉末状態で混合されている。なお、導電性炭素材料とエポキシ樹脂との混合比率は、重量（質量）比にして、導電性炭素材料：エポキシ樹脂＝６５：３５〜１００：５の範囲にあるともいえる。 The molding material for a fuel cell separator of the present invention (hereinafter also simply referred to as “molding material”) includes 65 to 100 parts by weight of conductive carbon material, 5 to 35 parts by weight of epoxy resin, and 100 parts by weight of epoxy resin. 5 parts by weight to 70 parts by weight of the curing agent and 0.1 part by weight to 5 parts by weight of the charge control agent for 100 parts by weight of the carbon material, the epoxy resin, and the curing agent. Here, the above-mentioned materials are mixed in a powder state. In addition, it can be said that the mixing ratio of the conductive carbon material and the epoxy resin is in the range of conductive carbon material: epoxy resin = 65: 35 to 100: 5 in terms of weight (mass) ratio.
このような成形材料では、帯電制御剤によって、成形材料を構成する各粉末を均一に分散させることができる。このため、安息角が小さく、成形性に優れる燃料電池用セパレータ用成形材料とすることができる。また、最終的に成形された燃料電池用セパレータ（以下、単に「セパレータ」ともいう）に適切な導電性と機械的強度とを賦与できる燃料電池セパレータ用成形材料とすることができる。 In such a molding material, each powder constituting the molding material can be uniformly dispersed by the charge control agent. For this reason, it can be set as the molding material for fuel cell separators with a small angle of repose and excellent moldability. Moreover, it can be set as the molding material for fuel cell separators which can give appropriate electroconductivity and mechanical strength to the fuel cell separator (hereinafter also simply referred to as “separator”).
本発明の成形材料では、上記粉末の他に、加圧成形時に成形温度付近における硬化を促進させるための補助硬化剤としての役割を担う硬化促進剤が含まれていてもよい。硬化促進剤は、例えば、硬化剤１００重量部に対して０．１重量部〜１０重量部の範囲で含まれていればよい。 In the molding material of the present invention, in addition to the above powder, a curing accelerator that serves as an auxiliary curing agent for accelerating curing near the molding temperature during pressure molding may be included. A hardening accelerator should just be contained in the range of 0.1 weight part-10 weight part with respect to 100 weight part of hardening | curing agents, for example.
本発明の成形材料では、上記粉末の他に、成形材料全体の充填率を高める役割を担う充填剤が含まれていてもよい。充填剤は、例えば、総重量部に対して１〜１０重量部の範囲で含まれていればよい。 In the molding material of this invention, the filler which plays the role which raises the filling rate of the whole molding material other than the said powder may be contained. The filler should just be contained in the range of 1-10 weight part with respect to total weight part, for example.
次に、本発明の成形材料を構成する各粉末の種類と、含有量の範囲の根拠について説明する。 Next, the type of each powder constituting the molding material of the present invention and the basis of the content range will be described.
導電性炭素材料の種類は特に限定されない。例えば、鱗状黒鉛や塊状黒鉛などの天然黒鉛、人造黒鉛、アセチレンブラック及びカーボンブラックから選ばれる少なくとも１種を用いればよい。本発明の成形材料中における導電性炭素材料の含有量が６５重量部未満の場合、最終的に成形されたセパレータの導電性が低下する可能性がある。また、導電性炭素材料の含有量が１００重量部を超過する場合、最終的に成形されたセパレータの導電性は向上するが、機械的強度が低下して振動などに対して脆弱になる可能性がある。 The kind of conductive carbon material is not particularly limited. For example, at least one selected from natural graphite such as scaly graphite and massive graphite, artificial graphite, acetylene black, and carbon black may be used. When the content of the conductive carbon material in the molding material of the present invention is less than 65 parts by weight, the conductivity of the finally molded separator may be lowered. In addition, when the content of the conductive carbon material exceeds 100 parts by weight, the conductivity of the finally formed separator is improved, but the mechanical strength may be lowered and become vulnerable to vibration. There is.
エポキシ樹脂は、上記炭素材料を結び付けるバインダーの役割を担う材料である。エポキシ樹脂の種類は特に限定されず、例えば、ビスフェノールＡ型やビスフェノールＦ型などのビスフェノール型樹脂、ノボラック−ビフェニル型樹脂およびビフェニルエステル型樹脂から選ばれる少なくとも１種を用いればよい。ただし、粉末状のエポキシ樹脂であることが好ましい。本発明の成形材料中におけるエポキシ樹脂の含有量が５重量部未満の場合、成形後に上記炭素材料を結び付ける結合力が低下して、最終的に成形されたセパレータの機械的強度が低下する可能性がある。また、エポキシ樹脂の含有量が３５重量部を超過する場合、上記炭素材料の相対的な含有量比が低下することによって、最終的に成形されたセパレータの導電性が低下する可能性がある。 The epoxy resin is a material that plays the role of a binder that binds the carbon material. The type of the epoxy resin is not particularly limited, and for example, at least one selected from bisphenol type resins such as bisphenol A type and bisphenol F type, novolak-biphenyl type resins, and biphenyl ester type resins may be used. However, it is preferably a powdery epoxy resin. When the content of the epoxy resin in the molding material of the present invention is less than 5 parts by weight, the bonding strength for binding the carbon material after molding may decrease, and the mechanical strength of the finally molded separator may decrease. There is. Moreover, when content of an epoxy resin exceeds 35 weight part, the electroconductivity of the finally shape | molded separator may fall by the relative content ratio of the said carbon material falling.
硬化剤は、本発明の成形材料を成形する際に、成形材料に含まれるエポキシ樹脂の硬化を促進させる役割を担っている。硬化剤の種類は、エポキシ樹脂を硬化できる種類であれば特に限定されない。例えば、酸無水物系樹脂、アミン系樹脂及びフェノール系樹脂から選ばれる少なくとも１種を用いればよい。成形されたセパレータの耐熱性の観点からは、ノボラック型フェノール系樹脂が好ましい。本発明の成形材料中における硬化剤の含有量が、上記エポキシ樹脂１００重量部に対して５重量部未満の場合、エポキシ樹脂の硬化速度と硬化程度とが不充分になる可能性がある。また、硬化剤の含有量が７０重量部を超過する場合、エポキシ樹脂の硬化は起こり易いものの、硬化速度が速すぎて成形性が悪くなる可能性がある。 The curing agent plays a role of promoting the curing of the epoxy resin contained in the molding material when the molding material of the present invention is molded. The kind of hardening agent will not be specifically limited if it is a kind which can harden | cure an epoxy resin. For example, at least one selected from acid anhydride resins, amine resins, and phenol resins may be used. From the viewpoint of the heat resistance of the molded separator, a novolac type phenol resin is preferable. When content of the hardening | curing agent in the molding material of this invention is less than 5 weight part with respect to 100 weight part of said epoxy resins, there exists a possibility that the hardening rate and hardening degree of an epoxy resin may become inadequate. Moreover, when content of a hardening | curing agent exceeds 70 weight part, although hardening of an epoxy resin will occur easily, a cure rate may be too quick and a moldability may worsen.
本発明の成形材料中において、帯電制御材は、上述した他の材料（導電性炭素材料、エポキシ樹脂、硬化剤など）の粉末粒子の表面が同じ極性を帯び、かつ、粉末粒子の帯電分布度を均一にさせる役割を担っている。各粉末粒子が同じ極性を帯びることによって、粒子間に相互反発力が働き、導電性炭素材料、エポキシ樹脂、硬化剤などの各種材料粉末を互いに均一に混合あるいは分散さることができる。このため、最終的に成形されたセパレータの導電性や機械的強度などを向上させることができる。 In the molding material of the present invention, the charge control material is such that the surface of the powder particles of the other materials (conductive carbon material, epoxy resin, curing agent, etc.) have the same polarity and the charge distribution degree of the powder particles. It plays a role to make uniform. When each powder particle has the same polarity, a mutual repulsive force acts between the particles, and various material powders such as a conductive carbon material, an epoxy resin, and a curing agent can be uniformly mixed or dispersed with each other. For this reason, the electroconductivity, mechanical strength, etc. of the separator shape | molded finally can be improved.
帯電制御剤には、例えば、電子複写機のトナー原料に用いられている材料を用いればよく、その種類は特に限定されない。具体的には、例えば、ニグロシン系染料、第４級アンモニウム塩、アゾ系含金染料、粉末状の金属酸化物が反応付着したモノアゾ染料の金属錯体系材料、サリチル酸系金属錯体及び粉末状の金属酸化物が反応付着したサリチル酸系金属錯体から選ばれる少なくとも１種を含む材料を用いればよい。このうち、ニグロシン系染料及び第４級アンモニウム塩などは、正帯電制御剤（粒子の表面を正に帯電させる）として作用し、アゾ系含金染料、粉末状の金属酸化物が反応付着したモノアゾ染料の金属錯体系材料、サリチル酸系金属錯体及び粉末状の金属酸化物が反応付着したサリチル酸系金属錯体などは、負帯電制御材（粒子の表面を負に帯電させる）として作用する。なかでも、適切な平均粒径を有する粉末状の金属酸化物を添加した金属錯体系の帯電制御剤が好ましい。なお、金属酸化物にはケイ素の酸化物（例えば、シリカなど）が含まれる。 As the charge control agent, for example, a material used for a toner raw material of an electronic copying machine may be used, and the kind thereof is not particularly limited. Specifically, for example, a nigrosine dye, a quaternary ammonium salt, an azo metal-containing dye, a metal complex material of a monoazo dye to which a powdered metal oxide is attached by reaction, a salicylic acid metal complex, and a powdered metal What is necessary is just to use the material containing at least 1 sort (s) chosen from the salicylic acid type metal complex to which the oxide adhered by reaction. Of these, nigrosine dyes and quaternary ammonium salts act as positive charge control agents (positively charge the surface of the particles), and monoazo azo dyes and powdered metal oxides react and adhere. A metal complex material of a dye, a salicylic acid metal complex, and a salicylic acid metal complex to which a powdered metal oxide is attached by reaction acts as a negative charge control material (charges the surface of the particles negatively). Among these, a metal complex type charge control agent to which a powdery metal oxide having an appropriate average particle diameter is added is preferable. The metal oxide includes a silicon oxide (for example, silica).
本発明の成形材料における帯電制御剤の含有量は、導電性炭素材料、エポキシ樹脂及び硬化剤の混合量１００重量部に対して０.１重量部〜５重量部の範囲であるが、帯電制御材の含有量が０.１重量部未満である場合、他の材料の粉末粒子を分散させる効果が十分に得られない可能性がある。また、帯電制御材の含有量が５.０重量部を超過しても構わないが、含有量が５.０重量部を超過した場合においても、粉末粒子の分散効果はそれ以上向上せずに一定であると考えられる。このため、帯電制御材は、必要以上添加する必要はないと考えられる。 The content of the charge control agent in the molding material of the present invention is in the range of 0.1 to 5 parts by weight with respect to 100 parts by weight of the mixed amount of the conductive carbon material, epoxy resin and curing agent. When the content of the material is less than 0.1 part by weight, the effect of dispersing the powder particles of the other material may not be sufficiently obtained. In addition, the content of the charge control material may exceed 5.0 parts by weight, but even when the content exceeds 5.0 parts by weight, the dispersion effect of the powder particles does not further improve. It is considered constant. For this reason, it is considered that the charge control material does not need to be added more than necessary.
硬化促進剤は必要に応じて添加すればよい。硬化促進剤は、本発明の成形材料を加圧成形する際に、金型温度付近でエポキシ樹脂の硬化を促進させる役割を担っている。硬化促進剤の種類は、金型温度に応じて選択すればよい。例えば、１５０℃近傍の温度で加圧成形する場合、１５０℃近傍でエポキシ樹脂の硬化反応を促進させる硬化促進剤であればよい。具体的には、例えば、イミダゾール系樹脂、ポリアミド系樹脂及び有機系樹脂から選ばれる少なくとも１種を用いればよい。本発明の成形材料における硬化促進剤の含有量が、硬化剤１００重量部に対して０.１重量部未満である場合、エポキシ樹脂の硬化を促進する効果が十分に得られない可能性がある。また、硬化促進剤の含有量が、１０重量部を超過する場合、金型に含まれる金属と硬化反応を起こすことによって反応ガスが発生したり、発生した反応ガスの排出が円滑に行われない可能性がある。このため、最終的に成形されたセパレータの機械的強度及び導電性が低下する可能性がある。 What is necessary is just to add a hardening accelerator as needed. The curing accelerator plays a role of accelerating the curing of the epoxy resin near the mold temperature when the molding material of the present invention is pressure-molded. What is necessary is just to select the kind of hardening accelerator according to metal mold temperature. For example, when pressure molding is performed at a temperature in the vicinity of 150 ° C., a curing accelerator that accelerates the curing reaction of the epoxy resin near 150 ° C. may be used. Specifically, for example, at least one selected from imidazole resins, polyamide resins, and organic resins may be used. When the content of the curing accelerator in the molding material of the present invention is less than 0.1 part by weight with respect to 100 parts by weight of the curing agent, the effect of promoting the curing of the epoxy resin may not be sufficiently obtained. . In addition, when the content of the curing accelerator exceeds 10 parts by weight, a reactive gas is generated by causing a curing reaction with the metal contained in the mold, and the generated reactive gas is not smoothly discharged. there is a possibility. For this reason, the mechanical strength and conductivity of the finally molded separator may be lowered.
充填剤は、導電性炭素材料粉末間の隙間を充填して、成形材料全体の充填率を高める役割を担っている。充填剤に用いる材料は、特に限定されず、例えば、シリカ、硫酸バリウム、アルミナ、酸化マグネシウム、炭酸カルシウム、雲母、カオリン、ベントナイトおよび水酸化アルミニウムから選ばれる少なくとも１種の材料を用いればよい。本発明の成形材料における充填剤の含有量が、成形材料１００重量部に対して１重量部未満である場合、充填率を高める効果が十分に得られない可能性がある。また、充填剤の含有量が、１０重量部を超過する場合、導電性炭素材料の重量に対する硬化剤の重量比が相対的に減少するため、最終的に成形されたセパレータの機械的強度及び導電性が低下する可能性がある。 The filler plays a role of filling the gaps between the conductive carbon material powders and increasing the filling rate of the entire molding material. The material used for the filler is not particularly limited, and for example, at least one material selected from silica, barium sulfate, alumina, magnesium oxide, calcium carbonate, mica, kaolin, bentonite, and aluminum hydroxide may be used. When the content of the filler in the molding material of the present invention is less than 1 part by weight with respect to 100 parts by weight of the molding material, the effect of increasing the filling rate may not be sufficiently obtained. In addition, when the filler content exceeds 10 parts by weight, the weight ratio of the curing agent to the weight of the conductive carbon material is relatively reduced, so that the mechanical strength and conductivity of the finally formed separator are reduced. May be reduced.
導電性炭素材料、エポキシ樹脂、硬化剤、帯電制御剤などの各材料粉末の大きさは特に限定されない。例えば、導電性炭素材料、エポキシ樹脂、硬化剤および帯電制御剤から選ばれる少なくとも１種の材料の平均粒径が、０．２μｍ〜２０μｍの範囲であればよい。なかでも、上記すべての材料の平均粒径が、０．２μｍ〜２０μｍの範囲にあることが好ましい。より良好な成形性を得ることができる。また、最終的に成形されたセパレータの機械的強度及び導電性をより向上できる。各材料の平均粒径が０.２μ未満である場合、各材料粉末の均一な分散を達成することが難しくなる可能性がある。また、各材料の平均粒径が２０μｍを超過する場合、成形後にセパレータの機械的強度が低下する可能性がある。 The size of each material powder such as a conductive carbon material, an epoxy resin, a curing agent, and a charge control agent is not particularly limited. For example, the average particle diameter of at least one material selected from a conductive carbon material, an epoxy resin, a curing agent, and a charge control agent may be in the range of 0.2 μm to 20 μm. Especially, it is preferable that the average particle diameter of all the said materials exists in the range of 0.2 micrometer-20 micrometers. Better moldability can be obtained. Further, the mechanical strength and conductivity of the finally formed separator can be further improved. When the average particle size of each material is less than 0.2 μm, it may be difficult to achieve uniform dispersion of each material powder. Moreover, when the average particle diameter of each material exceeds 20 micrometers, the mechanical strength of a separator may fall after shaping | molding.
上述した組成で混合される本発明の燃料電池セパレータ用成形材料では、１５°〜３０°程度の範囲の安息角を実現することができる。このため、本発明の成形材料は、加熱加圧成形モールド工程に安定的に投入することができる。 In the molding material for a fuel cell separator of the present invention mixed with the composition described above, an angle of repose in the range of about 15 ° to 30 ° can be realized. For this reason, the molding material of this invention can be stably injected | thrown-in to a heat-press molding mold process.
次に、本発明の成形材料を製造する方法と、本発明の成形材料を用いてセパレータを成形する工程について説明する。 Next, a method for producing the molding material of the present invention and a process for molding a separator using the molding material of the present invention will be described.
本発明の燃料電池セパレータ用成形材料は、例えば、以下に示す方法によって製造することができる。最初に、導電性炭素材料、エポキシ樹脂及び硬化剤のそれぞれをハンマークラッシャー(hammer crusher)などを用いて平均粒径５０μｍ〜３００μｍ程度の範囲になるまで粉砕する。次に、ジェットミル(jet mill)などを用いて上記材料のそれぞれを、さらに粉砕し、平均粒径が０.２μｍ〜２０μｍ程度の範囲の各材料粉末を形成する。次に、形成した上記各粉末と帯電制御剤とをミキサに入れて乾式で混合することによって、本発明の燃料電池セパレータ用成形材料の粉末を製造することができる。 The molding material for a fuel cell separator of the present invention can be produced, for example, by the following method. First, each of the conductive carbon material, the epoxy resin, and the curing agent is pulverized using a hammer crusher or the like until the average particle size is in the range of about 50 μm to 300 μm. Next, each of the above materials is further pulverized using a jet mill or the like to form each material powder having an average particle size in the range of about 0.2 μm to 20 μm. Next, the powder of the molding material for a fuel cell separator of the present invention can be produced by mixing the formed powder and the charge control agent in a mixer and mixing them in a dry manner.
一方、最終的に成形されたセパレータの導電性および／または機械的強度などをさらに向上させるために、乾式で混合された前記成形材料粉末を２軸混練機などによって加熱混練して冷却した後、ジェットミルなどで粉砕して平均粒径０.２μｍ〜２０μｍの範囲に微粉砕して本発明の成形材料粉末を製造することもできる。 On the other hand, in order to further improve the conductivity and / or mechanical strength of the finally molded separator, the molding material powder mixed in a dry process is heated and kneaded with a biaxial kneader or the like, and then cooled. The molding material powder of the present invention can also be produced by pulverizing with a jet mill or the like and finely pulverizing to an average particle size of 0.2 μm to 20 μm.
本発明の成形材料を用いてセパレータを成形するためには、例えば、以下のように行えばよい。本発明の成形材料を加圧成形モールドに入れて５００ｋｇ／ｃｍ2〜１０００ｋｇ／ｃｍ2程度の圧力を与えた状態で、１３０℃〜２００℃程度の温度で１分〜５分間程度加熱すればよい。モールドの金型は、得たいセパレータの形状に合わせて、任意に設定すればよい。 In order to mold the separator using the molding material of the present invention, for example, the following may be performed. In a state where the molding material gave a pressure of about 2 pressing placed in the mold 500kg / cm 2 ~1000kg / cm of the present invention may be heated for about 1 minute to 5 minutes at a temperature of about 130 ° C. to 200 DEG ° C. . What is necessary is just to set the metal mold | die of a mold arbitrarily according to the shape of the separator to obtain.
本発明の成形材料で作られたセパレータの特性は、以下に示す実施例と比較例とによってより明確に理解されるであろう。 The characteristics of the separator made of the molding material of the present invention will be more clearly understood from the following examples and comparative examples.
（実施例１）
導電性炭素材料として塊状黒鉛７０重量部、エポキシ樹脂としてビスフェノールＡ型エポキシ樹脂２０重量部、硬化剤としてノボラック型フェノール樹脂５重量部（エポキシ樹脂１００重量部に対して２５重量部）のそれぞれを、ハンマークラッシャーを用いて平均粒径２５０μｍに粉砕した後、各粉末をジェットミルで平均粒径５μｍに微粉砕して全体９５重量部の粉末を得た。
Example 1
70 parts by weight of massive graphite as the conductive carbon material, 20 parts by weight of bisphenol A type epoxy resin as the epoxy resin, and 5 parts by weight of novolac type phenol resin as the curing agent (25 parts by weight with respect to 100 parts by weight of the epoxy resin) After pulverizing to an average particle size of 250 μm using a hammer crusher, each powder was finely pulverized to an average particle size of 5 μm using a jet mill to obtain a total of 95 parts by weight of powder.
その後、前記各粉末と、負帯電制御剤としてシリカが反応付着したモノアゾ染料の鉄錯体系材料（平均粒径１μｍ）０．５重量部（黒鉛、エポキシ樹脂及び硬化剤１００重量部に対して０.５２６重量部）とを、ヘンシェルミキサ(Hensel mixer)に入れ、撹拌翼の速度を３２ｍ／ｓとして回転させながら乾式混合し、平均粒径５μｍ、安息角２１°の燃料電池セパレータ用成形材料９５.５重量部を製造した。乾式混合の方法は、以降の実施例、比較例においても同様である。 Thereafter, 0.5 parts by weight of the iron complex material of monoazo dye (average particle diameter 1 μm) to which silica is reactively attached as a negative charge control agent (0 to 100 parts by weight of graphite, epoxy resin and curing agent) 526 parts by weight) was placed in a Hensel mixer, and dry-mixed while rotating at a stirring blade speed of 32 m / s. The molding material 95 for fuel cell separators having an average particle size of 5 μm and an angle of repose of 21 ° 95 0.5 parts by weight were produced. The dry mixing method is the same in the following examples and comparative examples.
次に、上記のようにして作製した成形材料粉末を加圧成形モールドに入れ、６００ｋｇ／ｃｍ2の圧力下において１５０℃で２分間加熱して燃料電池用セパレータを成形した。このようにして得られたセパレータは、導電性を示す体積固有抵抗値（ＪＩＳ Ｋ ７１９４に基づく値、以降の実施例、比較例においても同様）が１２ｍΩ・ｃｍ、機械的曲げ強度（ＪＩＳ Ｋ ７２０３に基づく値、以降の実施例、比較例においても同様）が６５ＭＰａであった。 Next, the molding material powder produced as described above was placed in a pressure molding mold and heated at 150 ° C. for 2 minutes under a pressure of 600 kg / cm 2 to form a fuel cell separator. The separator thus obtained has a volume specific resistance value indicating conductivity (value based on JIS K 7194, the same applies to the following examples and comparative examples) of 12 mΩ · cm, mechanical bending strength (JIS K 7203). And the same applies to the following examples and comparative examples) was 65 MPa.
（比較例１）
導電性炭素材料として塊状黒鉛７０重量部、エポキシ樹脂としてビスフェノールＡ型エポキシ樹脂２０重量部、硬化剤としてノボラック型フェノール樹脂５重量部のそれぞれを、ハンマークラッシャーを用いて平均粒径２５０μｍに粉砕した後、各粉末をジェットミルで平均粒径５μｍに微粉砕して全体９５重量部の粉末を得た。
(Comparative Example 1)
After pulverizing 70 parts by weight of massive graphite as a conductive carbon material, 20 parts by weight of bisphenol A type epoxy resin as an epoxy resin, and 5 parts by weight of novolac type phenol resin as a curing agent, each using a hammer crusher to an average particle size of 250 μm Each powder was finely pulverized with a jet mill to an average particle size of 5 μm to obtain a total of 95 parts by weight of powder.
その後、前記各粉末を、帯電制御剤を添加することなく乾式混合してセパレータ用成形材料９５重量部を得た。この際、成形材料の平均粒径は５μｍ、安息角は３１°であった。 Thereafter, the powders were dry mixed without adding a charge control agent to obtain 95 parts by weight of a molding material for a separator. At this time, the average particle diameter of the molding material was 5 μm, and the angle of repose was 31 °.
次に、上記のようにして作製した成形材料を用いて、実施例１と同一の条件でセパレータを成形した。このようにして得られたセパレータの体積固有抵抗は１５ｍΩ・ｃｍ、機械的曲げ強度は６１ＭＰａであった。 Next, a separator was molded under the same conditions as in Example 1 using the molding material produced as described above. The separator thus obtained had a volume resistivity of 15 mΩ · cm and a mechanical bending strength of 61 MPa.
（実施例２）
導電性炭素材料として鱗状黒鉛８４重量部及びアセチレンブラック(acetylene black)１重量部、エポキシ樹脂としてビスフェノールＡ型エポキシ樹脂１０重量部、硬化促進剤として２−イミダゾール０.２重量部が添加された硬化剤であるノボラック型フェノール樹脂６.２重量部のそれぞれを、平均粒径６０μｍに１次粉砕した後、ジェットミルを用いて各粉末の平均粒径が１６μｍとなるように微粉砕し、全体１０１.２重量部の粉末を得た。
(Example 2)
Curing in which 84 parts by weight of scaly graphite as conductive carbon material and 1 part by weight of acetylene black, 10 parts by weight of bisphenol A type epoxy resin as epoxy resin, and 0.2 part by weight of 2-imidazole as curing accelerator are added. Each of 6.2 parts by weight of the novolak type phenol resin as the agent was first ground to an average particle size of 60 μm, and then finely pulverized using a jet mill so that the average particle size of each powder was 16 μm. 0.2 part by weight of powder was obtained.
その後、前記各粉末と、負帯電制御材としてサリチル酸クロム錯体（平均粒径０.８μｍ）２重量部とを乾式混合した。このようにして作製した成形材料１０３.２重量部の平均粒径は１６μｍ、安息角は２４°であった。 Thereafter, each of the powders and 2 parts by weight of a chromium salicylate complex (average particle size: 0.8 μm) as a negative charge control material were dry mixed. The average particle diameter of 103.2 parts by weight of the molding material thus prepared was 16 μm and the angle of repose was 24 °.
次に、上記のようにして作製した成形材料を加圧成形モールドに入れ、１０００ｋｇ／ｃｍ2の圧力を与えた状態において２００℃で１分間加熱してセパレータを成形した。このようにして得られたセパレータの体積固有抵抗は１３ｍΩ・ｃｍ、機械的曲げ強度は６５ＭＰａであった。 Next, the molding material produced as described above was put into a pressure molding mold, and heated at 200 ° C. for 1 minute in a state where a pressure of 1000 kg / cm 2 was applied, thereby molding a separator. The separator thus obtained had a volume resistivity of 13 mΩ · cm and a mechanical bending strength of 65 MPa.
（比較例２）
実施例２と同様の導電性炭素材料、エポキシ樹脂及び硬化促進剤を含む硬化剤を用い、帯電制御剤が添加されていない成形材料１０１.２重量部を実施例２と同様の方法で製造した。作製した成形材料は、その平均粒径が１６μｍ、安息角が３４°であった。次に、実施例２と同様の方法を用いてセパレータを製造した。得られたセパレータの体積固有抵抗は１８ｍΩ・ｃｍ、機械的曲げ強度は５９ＭＰａであった。
(Comparative Example 2)
Using the same conductive carbon material as in Example 2, a curing agent containing an epoxy resin and a curing accelerator, 101.2 parts by weight of a molding material to which no charge control agent was added was produced in the same manner as in Example 2. . The produced molding material had an average particle size of 16 μm and an angle of repose of 34 °. Next, a separator was manufactured using the same method as in Example 2. The obtained separator had a volume resistivity of 18 mΩ · cm and a mechanical bending strength of 59 MPa.
（実施例３）
導電性炭素材料として塊状黒鉛９３重量部、エポキシ樹脂としてビスフェノールＦ型エポキシ樹脂２５重量部、硬化剤としてノボラック型フェノール樹脂２重量部、充填剤として炭酸カルシウム２重量部のそれぞれを、実施例１と同様にして平均粒径１００μｍに粉砕した後、各粉末を平均粒径９μｍに微粉砕して全体１２２重量部の粉末を得た。
Example 3
Example 1 includes 93 parts by weight of massive graphite as the conductive carbon material, 25 parts by weight of bisphenol F type epoxy resin as the epoxy resin, 2 parts by weight of novolac type phenol resin as the curing agent, and 2 parts by weight of calcium carbonate as the filler. Similarly, after pulverizing to an average particle size of 100 μm, each powder was finely pulverized to an average particle size of 9 μm to obtain a total of 122 parts by weight of powder.
その後、前記各粉末と、正帯電制御剤として第４級アンモニウム塩５重量部（平均粒径３μｍ）とを乾式混合した。次に、形成した混合物を、２軸混練機を用いて１２０℃で混練して冷却した後、ジェットミルを用いて微粉砕し、平均粒径を１０μｍの成形材料粉末を得た。作製した成形材料１２７重量部の安息角は１７°であった。 Thereafter, the powders were mixed with 5 parts by weight of a quaternary ammonium salt (average particle size: 3 μm) as a positive charge control agent. Next, the formed mixture was kneaded at 120 ° C. using a twin-screw kneader, cooled, and then finely pulverized using a jet mill to obtain a molding material powder having an average particle diameter of 10 μm. The repose angle of 127 parts by weight of the produced molding material was 17 °.
次に、上記のようにして作製した成形材料を８００ｋｇ／ｃｍ2の圧力下において１８０℃で４分間加熱してセパレータを成形した。このようにして得られたセパレータの体積固有抵抗は１１ｍΩ・ｃｍ、機械的曲げ強度は６７ＭＰａであった。 Next, the molding material produced as described above was heated at 180 ° C. for 4 minutes under a pressure of 800 kg / cm 2 to mold a separator. The separator thus obtained had a volume resistivity of 11 mΩ · cm and a mechanical bending strength of 67 MPa.
（比較例３）
実施例３と同様の導電性炭素材料、エポキシ樹脂、硬化剤及び充填剤を用い、帯電制御剤が添加されていない成形材料１２２重量部を、実施例３と同様の方法で製造した。作製した成形材料は、その平均粒径が１０μｍ、安息角が３２°であった。次に、実施例３と同様の方法を用いてセパレータを製造した。得られたセパレータの体積固有抵抗は１７ｍΩ・ｃｍ、機械的曲げ強度は６０ＭＰａであった。
(Comparative Example 3)
Using the same conductive carbon material, epoxy resin, curing agent and filler as in Example 3, 122 parts by weight of a molding material to which no charge control agent was added was produced in the same manner as in Example 3. The produced molding material had an average particle size of 10 μm and an angle of repose of 32 °. Next, a separator was manufactured using the same method as in Example 3. The obtained separator had a volume resistivity of 17 mΩ · cm and a mechanical bending strength of 60 MPa.
上述した各実施例と比較例とにおける、成形材料粉末の物理的特性と、各成形材料で作られたセパレータの体積固有抵抗及び機械的曲げ強度を表１にまとめた。 Table 1 summarizes the physical characteristics of the molding material powder and the volume resistivity and mechanical bending strength of the separator made of each molding material in each of the above-described Examples and Comparative Examples.
（表１）
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
サンプル 平均粒径 安息角 体積固有抵抗値 機械的曲げ強度
(μｍ) (°) (ｍΩ・ｃｍ) (ＭＰａ)
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
実施例１ ５ ２１ １２ ６５
比較例１ ５ ３１ １５ ６１
実施例２ １６ ２４ １３ ６５
比較例２ １６ ３４ １８ ５９
実施例３ １０ １７ １１ ６７
比較例３ １０ ３２ １７ ６０
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
(Table 1)
--------------------------------
Sample Average particle diameter Repose angle Volume resistivity Mechanical bending strength
(μm) (°) (mΩ ・ cm) (MPa)
--------------------------------
Example 1 5 21 12 65
Comparative Example 1 5 31 15 61
Example 2 16 24 13 65
Comparative Example 2 16 34 18 59
Example 3 10 17 11 67
Comparative Example 3 10 32 17 60
--------------------------------
表１に示すように、実施例として作製した成形材料と、比較例として作製した成形材料とでは、同一の平均粒径を有しているにも関わらず、帯電制御剤の有無によって、成形材料の成形性に影響を及ぼすと考えられる安息角が相異することがわかる。また、帯電制御剤の存在が、最終的に成形されるセパレータの導電性及び機械的曲げ強度にも影響を及ぼしていることが分かる。 As shown in Table 1, the molding material produced as an example and the molding material produced as a comparative example have the same average particle diameter, but the molding material depends on the presence or absence of a charge control agent. It can be seen that the angle of repose, which is considered to affect the moldability of the resin, is different. It can also be seen that the presence of the charge control agent affects the conductivity and mechanical bending strength of the separator finally formed.
即ち、帯電制御剤を含む本発明の成形材料とすることによって、成形材料に含まれる各粉末の分散均一性を向上することができ、安息角を低下させることができる。このため、成形材料の成形性を向上することができ、結果、最終成形体である燃料電池用セパレータの導電性および機械的特性を向上することができる。 That is, by using the molding material of the present invention containing a charge control agent, the dispersion uniformity of each powder contained in the molding material can be improved, and the angle of repose can be lowered. For this reason, the moldability of the molding material can be improved, and as a result, the conductivity and mechanical properties of the fuel cell separator that is the final molded body can be improved.
以上、説明したように、本発明によれば、帯電制御剤を含有することによって、導電性炭素材料、エポキシ樹脂、硬化剤などの各粉末が非常に均一に分散・混合できるため、安息角が小さく、成形性に優れ、最終成形後に適切な導電性と機械的強度が実現可能である燃料電池セパレータ用成形材料を提供することができる。 As described above, according to the present invention, by including a charge control agent, each powder of conductive carbon material, epoxy resin, curing agent and the like can be dispersed and mixed very uniformly, so the angle of repose is It is possible to provide a molding material for a fuel cell separator that is small, excellent in moldability, and capable of realizing appropriate electrical conductivity and mechanical strength after final molding.
本発明の燃料電池セパレータ用成形材料によって成形されたセパレータは、高分子電解質型燃料電池（ＰＥＭＦＣ）、ダイレクトメタノール型燃料電池（ＤＭＦＣ）などの用途に用いることができる。 The separator formed by the molding material for a fuel cell separator of the present invention can be used for applications such as a polymer electrolyte fuel cell (PEMFC) and a direct methanol fuel cell (DMFC).
Claims (9)
エポキシ樹脂５重量部〜３５重量部と、
前記エポキシ樹脂１００重量部に対する硬化剤５重量部〜７０重量部と、
前記炭素材料、前記エポキシ樹脂及び前記硬化剤の混合量１００重量部に対する帯電制御剤０.１重量部〜５重量部とを含み、
前記帯電制御剤が、粉末状の金属酸化物が反応付着したモノアゾ染料の金属錯体系材料を含むことを特徴とする燃料電池セパレータ用成形材料。 65 to 100 parts by weight of conductive carbon material,
5 to 35 parts by weight of epoxy resin,
5 parts by weight to 70 parts by weight of a curing agent with respect to 100 parts by weight of the epoxy resin;
The carbon material, viewed including the said epoxy resin and a charge control agent 0.1 to 5 parts by weight with respect to mixing amount 100 parts by weight of the curing agent,
A molding material for a fuel cell separator , wherein the charge control agent includes a metal complex material of a monoazo dye to which a powdered metal oxide is reactively attached .
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| JP2006249338A (en) * | 2005-03-11 | 2006-09-21 | Nichias Corp | Electroconductive epoxy resin composition and separator for fuel cell |
| KR100812269B1 (en) * | 2006-11-22 | 2008-03-13 | 한국타이어 주식회사 | Method for producing composite material for fuel cell separator |
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| WO2008120830A1 (en) * | 2007-03-30 | 2008-10-09 | Gs Caltex Corporation | Composition for source particle of high-temperature typed bipolar plate for fuel cell and high-temperature typed bipolar plate for fuel cell manufactured by using the same |
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