JP4944051B2 - 固体電解質複層フィルム及びその製造方法 - Google Patents
固体電解質複層フィルム及びその製造方法 Download PDFInfo
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- JP4944051B2 JP4944051B2 JP2008027390A JP2008027390A JP4944051B2 JP 4944051 B2 JP4944051 B2 JP 4944051B2 JP 2008027390 A JP2008027390 A JP 2008027390A JP 2008027390 A JP2008027390 A JP 2008027390A JP 4944051 B2 JP4944051 B2 JP 4944051B2
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Images
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
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Description
また、本発明の前記固体電解質複層フィルムの製造方法は、固体電解質であるポリマーからなる固体電解質膜の一面に、光重合性モノマー化13または化14を含む第1のモノマー層を形成する第1工程と、前記固体電解質膜の他面に、前記光重合性モノマー化13または化14を含む第2のモノマー層を形成する第2工程と、前記第1のモノマー層と前記第2のモノマー層とにそれぞれ光を照射して、前記光重合性モノマー化13または化14を重合させる重合工程と、を有することを特徴とする。
本発明は、後述の製造法によりフィルムとする固体電解質として、プロトン供与基をもつポリマーを用いている。プロトン供与基をもつポリマーは、特に限定されないが、酸残基をもち、プロトン伝導材料として公知であるものを用いることができる。中でも好ましいポリマーは、酸残基をもつものであり、例えば、側鎖にスルホン酸を有する付加重合高分子化合物、側鎖リン酸基ポリ(メタ)アクリレート、ポリエーテルエーテルケトンをスルホン化したスルホ化ポリエーテルエーテルケトン、スルホ化ポリベンズイミダゾール、ポリスルホンをスルホン化したスルホ化ポリスルホン、耐熱性芳香族高分子化合物のスルホ化物などが挙げられる。側鎖にスルホン酸を有する付加重合高分子化合物としては、ナフィオン(登録商標)に代表されるパーフルオロスルホン酸や、スルホ化ポリスチレン、スルホ化ポリアクリロニトリルスチレン、スルホ化ポリアクリロニトリルブタジエンスチレンなどがあり、耐熱性芳香族高分子のスルホ化物としてはスルホ化ポリイミド等がある。
(1)浸漬液102と流延膜61中に含まれる溶媒の一部との置換により、残留溶媒量が低減する。
(2)前駆体の貧溶媒である浸漬液102に浸漬することにより、流延膜61が固化する。
こうして、剥取ローラ100により、自己支持性を有する流延膜61を前駆体膜65として容易に剥ぎ取ることができると同時に、後の第1乾燥工程67における、前駆体膜65の残留溶媒の除去に要する時間を短縮することができる。なお、流延膜61から添加剤が浸漬液102中に溶け出る、流出する等の場合には、流延膜61の浸漬液102への浸漬は実施せず、前駆体膜65、水素置換膜68がある程度乾いたところで、後述のようにモノマー91を塗布して第1,第2表層を形成し、その後、浸漬液102へ浸漬して乾燥を再び行うとよい。
酸処理室84には、図3に示すとおり、酸浸漬槽110と電圧印加槽111と水槽112とが、上流側から順に設けられる。
酸浸漬槽110には、プロトン供与体である酸を含む液(以下、第1液と称する)300が貯留する。酸浸漬槽110には、温調機115が備えられ、温調機115は、酸浸漬槽110に貯留する第1液300の温度を所定の範囲に保持する。さらに、酸浸漬槽110には、第1液300中に浸漬するようにローラ116、117が設けられる。ローラ116は、耳切装置105から送られる前駆体膜65を、第1液300内へ案内する。こうして、前駆体膜65と第1液300との接触により、前駆体膜65に酸処理が施され、前駆体が固体電解質となり、水素置換膜68が得られる。なお、固体電解質層をPBIとリン酸との複合材料により形成する場合には、PBIを含むドープを流延し、第1液300に代えてリン酸水溶液とするとよい。この場合のリン酸水溶液はPBIに対するプロトン供与体ではなく、複合材料の一材料として作用する。そして、ローラ117は、水素置換膜68を第1液300の外へ案内する。図3には、2つのローラ116、117が酸浸漬槽110内に設けられる様子を示しているが、これに限らず、1つまたは3つ以上のローラを酸浸漬槽110に設けても良い。なお、前駆体膜65から添加剤が第1液300中に溶け出る、流出する等の場合には、前駆体膜65の第1液300との接触は実施せず、前駆体膜65がある程度乾いたところで、後述のようにモノマー91を塗布して第1,第2表層を形成し、その後、浸漬液102へ浸漬して乾燥を再び行うとよい。
第1液300に含まれる酸として、例えば、硫酸、リン酸、硝酸や各種の有機酸を用いることができる。このうち、次工程である電圧印加工程での効果を高めるためには、有機酸、中でも、酢酸、プロピオン酸、酪酸、ギ酸、コハク酸、イソ酪酸、吉草酸、イソ吉草酸、カプロン酸、ベンゼンスルホン酸、安息香酸、アクリル酸、マロン酸、クエン酸、シュウ酸、イタコン酸、フマル酸、一般式(1)で表される化合物のいずれかひとつであることが好ましい。
R−AR−SO3H ・・・(1)
(ただし、Rは炭素数1〜6のアルキル基、アルコキシ基、アミド基のいずれかひとつであり、ARはベンゼン環とナフタレン環とのいずれか一方である)
電圧印加槽111には、第2液301が貯留し、1対の電極120,121と、ローラ122,123とが設けられる。第2液301には、水素置換膜68とともに導かれてきた第1液300が含まれている。第2液302に導かれた第1液300は水素置換膜68の中に含まれたものであり、水素置換フィルムの表面に付着していたものも含まれる。なお、製造開始時には、第2液301中における酸の濃度が薄すぎて電圧印加をしても電流が流れない場合もあるので、このような場合には、第1液301と同じあるいは他の酸を予め加えておいてもよい。第1液300に有機酸以外の上記酸を用いた場合には、有機酸を第2液中に入れておくとよい。この有機酸としては、第1液300の成分としての各種有機酸が挙げられる。
第2液301として、酸を含む液を用いることができる。第2液301のプロトン濃度の調節により、上述した通電条件を満足させることができる。第2液301に含まれるプロトン濃度は、特に限定されるものではない。なお、第2液301としては、酸を含む液を用いることが好ましい。
理論希釈倍率 = 洗浄液305の塗布量[ml/m2]÷第1液300の塗布量[ml/m2]
(B−1)ひとつのダイから、固体電解質ドープと第1表層ドープと第2表層ドープとを重なるように流出して3つのドープが重なる流延膜を形成する方法。
(B−2)走行する支持体の上方に、走行方向の上流側から順に、第1表層ドープを流出する流延ダイ、固体電解質層ドープを流出する流延ダイ、第2表層ドープを流出する流延ダイを順に配してドープの層を順に重ねていき3層の流延膜を形成する方法。
以下に、複層フィルムを電極膜複合体(Membrane and Electrode Assembly,以下、MEAと称する)に使用する例と、この電極膜複合体を燃料電池に用いる例とを説明する。ただし、ここに示すMEA及び燃料電池の形態は本発明の一例であり、本発明はこれに限定されない。図4は、MEAの断面概略図である。MEA261は、複層フィルム11と、この複層フィルム11を挟んで対向するアノード電極262及びカソード電極263とを備える。
(1)プロトン伝導材料塗布法:活性金属担持カーボン、プロトン伝導材料、溶媒を含む触媒ペースト(インク)を複層フィルム11の両面に直接塗布し、多孔質導電シート262a,263aを(熱)塗布層に圧着して5層構成のMEAを作製する。
(2)多孔質導電シート塗布法:触媒層262b,263bの材料を含んだ液、例えば触媒ペーストを、多孔質導電シート262a,263aの表面に塗布し、触媒層262b,263bを形成させた後、複層フィルム11と圧着し、5層構成のMEA261を作製する。
(3)Decal法:触媒ペーストをPTFE上に塗布し、触媒層262b,263bを形成させた後、複層フィルム11に触媒層262b,263bのみをうつし、3層構造を形成し、これに多孔質導電シート262a,263aを圧着し、5層構成のMEA261を作製する。
(4)触媒後担持法:白金未担持カーボン材料をプロトン伝導材料とともに混合したインクを複層フィルム11、多孔質導電シート262a,263aあるいはPTFE上に塗布・製膜した後、白金イオンを含む液に複層フィルム11を含浸させ、白金粒子を複層フィルム11中で還元析出させて触媒層262b,263bを形成させる。触媒層262b,263bを形成させた後は、上記(1)〜(3)の方法にてMEA261を作製する。
・前駆体; 100重量部
・溶媒成分1;ジメチルスルホキシド 256重量部
・溶媒成分2;メタノール 171重量部
2.ドープ24中に含ませた化合物の種類である。「A」は添加剤としてのリンタングステン酸であり、「B」は複合材料の一部となるリン酸である。
3.上記2の化合物のドープ24における重量比率である。上記2の化合物の重量をx1、ポリマー成分の重量をy1とするときに、100×x1/y1で求められる値(単位;重量%)である。
6.塗布液及び第1,第2表層ドープにおけるモノマー91の重量比。モノマー91の重量をx2、バインダ成分の重量をy2とするときに、100×x2/(x2+y2)で求める値(単位;wt%)である。
8.モノマー91を重合させるための光照射における光強度(単位;W/cm2)。照射した光は紫外線である。
9.モノマー91を重合させるための光照射時間(単位;秒)。
11.複層フィルム11及び単層フィルムの柔軟性。評価方法は、JIS−P−8115による。複層フィルム11、単層フィルムが割れなかった場合を「○」とし、割れた場合を「×」とした。
13.得られた複層フィルムまたは単層フィルムを25℃の水中に2時間浸漬し、浸漬前と浸漬後との重量の比率を求めた。表1には、浸漬前のフィルムの重量をx5,浸漬後のフィルムの重量をy5としたときに、100×y5/x5で求める値を記す。
13 固体電解質層
14,15 第1表層,第2表層
33 フィルム製造設備
T1 第1表層の厚み
T2 第2表層の厚み
T3 固体電解質層の厚み
Claims (4)
- 前記固体電解質層の厚みは10μm以上200μm以下の範囲で一定であり、
前記各疎水層の厚みは0.1μm以上10μm以下の範囲で一定であることを特徴とする請求項1記載の固体電解質複層フィルム。 - 前記有機材料に、さらに弾性あるいは柔軟性がバインダ成分により付与されていることを特徴とする、請求項1又は2記載の固体電解質複層フィルム。
- 固体電解質であるポリマーからなる固体電解質膜の一面に、光重合性モノマー化11または化12を含む第1のモノマー層を形成する第1工程と、
前記固体電解質膜の他面に、前記光重合性モノマー化11または化12を含む第2のモノマー層を形成する第2工程と、
前記第1のモノマー層と前記第2のモノマー層とにそれぞれ光を照射して、前記光重合性モノマー化11または化12を重合させる重合工程と、
を有することを特徴とする請求項1〜3のいずれか一つ記載の固体電解質複層フィルムの製造方法。
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