JP5821330B2 - Fuel cell catalyst manufacturing equipment - Google Patents

Description

  The present invention relates to a method for producing a fuel cell catalyst and an apparatus therefor.

The fuel cell has a structure in which a reaction layer is stacked on a solid electrolyte membrane, and the characteristics of the reaction layer on the air electrode side that is the fuel cell reaction field greatly influence the performance of the fuel cell.
The present inventor, as the air electrode side reaction layer, has a reaction layer (hereinafter referred to as “PFF (registered trademark: the same applies hereinafter) type reaction layer”) in which the periphery of the catalyst is surrounded by a polymer electrolyte phase via an aqueous phase. (Patent Document 1). Here, the catalyst is obtained by supporting catalyst metal particles on a carrier made of carbon particles or the like.
Refer to Patent Document 2 and Non-Patent Document 1 as documents disclosing techniques related to the present invention.

JP 2006-140061 A Japanese Patent Laid-Open No. 7-134995 “Carbon” p199 (Kim Kinoshita; John Wiley & Sons 1988)

For the catalytic metal particles, fine particles of expensive noble metal such as platinum are employed. In order to reduce the manufacturing cost of fuel cells and to promote the spread of fuel cells, it is important to reduce the amount of catalyst metal particles used.
The present invention is to improve the catalyst applied to the PPF type reaction layer and reduce the amount of the catalyst metal particles used.

As a result of intensive studies to solve the above-mentioned problems, the present inventor conducted a chemical treatment in which the surface of the catalytic metal particle was modified with a hydrophilic group, thereby stabilizing the PFF structure and improving the characteristics of the reaction layer. As a result, it has been found that the amount of catalyst metal particles used can be reduced.
As a result of further studies, the inventors have found that the hydrophilic group is rapidly modified with respect to the catalytic metal particles, and have arrived at the present invention.
That is, the first aspect of the present invention is defined as follows.
Preparing a raw material catalyst having catalyst metal particles supported on a carrier;
Mixing the raw material catalyst with water to produce a raw material catalyst slurry;
Modifying the catalytic metal particles of the raw material catalyst with a hydrophilic group,
The modifying step comprises transporting the raw material catalyst slurry through a pipe line, and adding the aqueous solution containing the hydrophilic group to the raw material catalyst slurry being transported for mixing. For producing a catalyst for use.

  According to the method for producing a fuel cell catalyst defined in the first aspect configured as described above, an aqueous solution containing a hydrophilic group is added on the way of conveying the raw catalyst slurry by a pipe line, thereby The catalytic metal particles can be modified with a hydrophilic group. Therefore, since the conveying pipe line also serves as a mixing reactor of the raw material catalyst slurry and the aqueous solution, the catalyst configuration is simplified and the catalyst that modifies the hydrophilic group on the catalytic metal particles of the raw material catalyst. The chemical treatment can be performed continuously. Thus, the manufacturing method which enables a continuous chemical treatment is suitable when manufacturing a catalyst in large quantities.

The second aspect of the present invention is defined as follows.
That is, in the method for producing a fuel cell catalyst defined in the first aspect, the catalytic metal particles are platinum or a platinum alloy, the hydrophilic group is a nitrate group, and the aqueous solution containing the hydrophilic group is hexahydroxoplatinum. It is a nitric acid solution of an acid.
By selecting the material specified in the second aspect, the chemical treatment of the catalyst for modifying the catalytic metal particles with a hydrophilic group can be performed as quickly and stably as possible.

The third aspect of the present invention is defined as follows.
That is, in the method for producing a fuel cell catalyst according to the second aspect, the nitric acid aqueous solution is diluted with water immediately before being added to the raw material catalyst slurry.
The raw material catalyst slurry conveyed through the pipe contains a large amount of moisture in order to reduce the pipe resistance. Similarly, it is preferable to add a nitric acid solution of hexahydroxoplatinic acid having a low concentration to the slurry having a low raw material catalyst concentration. On the other hand, when a nitric acid solution of hexahydroxoplatinic acid is diluted with water, water reacts with nitrate groups contained in the solution, and hexahydroxoplatinic acid may be precipitated as a solid. Therefore, as specified in the third aspect, it is preferable to dilute the nitric acid solution of hexahydroxoplatinic acid with water immediately before adding it to the slurry of the raw material catalyst.

The fourth aspect of the present invention is defined as follows. That is,
The method for producing a fuel cell catalyst defined in any one of the first to third aspects further includes a step of wet pulverizing the raw material catalyst slurry before introducing the raw material catalyst slurry into the conduit. .
According to the manufacturing method of the fourth aspect defined as described above, since the raw material catalyst slurry is wet-pulverized, the raw material catalyst is finely divided, and further, air or the like adsorbed from the raw material catalyst to this The gas is expelled and the aqueous solution easily comes into contact with the catalytic metal particles. Therefore, the hydrophilic group is modified to more catalytic metal particles. Thereby, the utilization factor of the catalyst metal particles is improved, and as a result, the reduction in the amount of the catalyst metal particles used is promoted.
In addition, in order to wet pulverize the raw material catalyst slurry, it is necessary to disperse the raw material catalyst in a large amount of water. This state is the same as the state of the raw material catalyst slurry when the raw material catalyst slurry is conveyed through the pipeline. Therefore, the raw material catalyst slurry before being introduced into the pipe line is subjected to a pulverization process by applying it to a wet pulverizer such as a homogenizer, and the pulverized raw material catalyst slurry can be directly introduced into the pipe line. Therefore, applying the wet pulverization process before introducing the raw material catalyst slurry into the pipe line is a simple process addition in the manufacturing process.

The fifth aspect of the present invention is defined as follows.
The catalytic metal particles as a raw material catalyst slurry mixing water to raw material catalyst comprising supported on a carrier, comprising a chemical treatment unit for mixing laden aqueous solution a hydrophilic group for modifying the catalytic metal particles, the hydrophilic group The aqueous solution contained is a nitric acid aqueous solution of hexahydroxoplatinic acid,
The chemical treatment unit includes a conduit formed to a length that the hexahydroxoplatinic acid is adsorbed while the raw material catalyst slurry is conveyed , and an injection unit that injects an aqueous solution containing the hydrophilic group connected to the conduit. An apparatus for producing a catalyst for a fuel cell, comprising:
The fuel cell catalyst production apparatus of the fifth aspect defined as described above can be used in the production method of the first aspect.
In the fuel cell catalyst manufacturing apparatus according to the fifth aspect, the catalytic metal particles are platinum or a platinum alloy, and the hydrophilic group is a nitrate group.

The sixth aspect of the present invention is defined as follows. That is,
In the fuel cell catalyst manufacturing apparatus according to the fifth aspect, a wet pulverizer for wet pulverizing the raw material catalyst slurry introduced into the pipe is disposed at the inlet of the pipe .
According to the fuel cell catalyst production apparatus of the sixth aspect defined as described above, the production method of the fourth aspect can be used.

The seventh aspect of the present invention is defined as follows. That is,
In the apparatus for producing a fuel cell catalyst according to the fifth or sixth aspect, a moisture adjusting device that adjusts the moisture content of the raw material catalyst slurry in which the catalytic metal particles are modified with a hydrophilic group and discharged from the conduit Is disposed at the outlet of the conduit .
The raw material catalyst slurry contains a large amount of water in order to efficiently transport the pipe, and a large amount of water remains in the slurry even after chemical treatment in the pipe. A slurry in which the catalyst is dispersed in water is sometimes referred to as a pre-paste. This pre-paste is mixed with the electrolyte solution to form a catalyst paste. However, the pre-paste to be mixed with the electrolyte solution has a suitable amount of moisture, and the slurry containing a large amount of water as described above has excess moisture and cannot be mixed with the electrolyte solution as it is.
Therefore, as specified in the seventh aspect, a moisture adjusting device is provided at the discharge port of the pipeline, and the moisture content of the slurry discharged from the pipeline is adjusted to be suitable for mixing with the electrolyte solution. It is preferable.

The eighth aspect of the present invention is defined as follows. That is,
A method for producing a reaction layer paste for a fuel cell by treating a catalyst having catalyst metal particles supported on a substrate,
A hydrophilic group adsorption step for chemically adsorbing hydrophilic groups to the catalytic metal particles;
Crushing step of wet crushing the catalyst,
The manufacturing method of the paste for reaction layers which performs the said hydrophilic group adsorption | suction step after performing the said crushing step.
According to the method for producing a reaction paste specified in this way, the catalyst is wet-pulverized, so that the catalyst is finely divided and gas such as air adsorbed on the catalyst is expelled from the catalyst. The hydrophilic group easily comes into contact with the catalytic metal particles. Therefore, the hydrophilic group is modified to more catalytic metal particles. Thereby, the utilization factor of the catalyst metal particles is improved, and as a result, the reduction in the amount of the catalyst metal particles used is promoted.

FIG. 1 is a sectional view showing the structure of a fuel cell according to an embodiment of the present invention. FIG. 2 is a schematic diagram of a PFF structure. 3A and 3B are schematic views showing the form of the electrolyte in the electrolyte solution. FIG. 3A shows a case where water is excessive, and FIG. 3B shows a case where water is appropriate. FIG. 4 is a schematic diagram showing the structure of the reaction layer corresponding to FIG. FIG. 5A shows the relationship between the stirring time and the viscosity of the pre-paste and the electrolyte solution, and FIG. 5B shows the relationship between the stirring time and the reaction layer resistance. It is a block diagram which shows the manufacturing apparatus of the catalyst paste of embodiment of this invention. It is a flowchart which similarly shows the manufacturing process of a catalyst paste. It is a schematic diagram which shows the structure of the mixing apparatus of the catalyst slurry and the nitric acid solution of hexahydroxoplatinic acid. It is a flowchart which shows the manufacturing process of the catalyst paste of other embodiment. It is an XPS chart of the catalyst of a test example. 3 is a graph showing characteristics of a fuel cell including a reaction layer obtained from catalyst pastes of Test Example 1, Comparative Example 1, and Comparative Example 2. 4 is a graph showing characteristics of a fuel cell including a reaction layer obtained from catalyst pastes of Example 1 and Comparative Example 1. 6 is a graph showing temperature characteristics of a fuel cell using the catalyst pastes of Example 2 and Reference Example 2.

A fuel cell 1 according to an embodiment of the present invention is shown in FIG.
This fuel cell 1 has a configuration in which a solid electrolyte membrane 2 is sandwiched between a hydrogen electrode 10 and an air electrode 20.
The solid electrolyte membrane 2 may be made of a proton conductive polymer material, for example, a fluorine-based polymer such as Nafion (trade name of DuPont, hereinafter the same).

The hydrogen electrode 10 includes a reaction layer 11 and a diffusion layer 16, and is sequentially stacked on the solid electrolyte membrane 2. The reaction layer 11 is obtained by coating an electroconductive carrier such as carbon particles with catalyst metal particles such as platinum (catalyst) coated with an electrolyte. The diffusion layer 16 is made of a conductive material such as carbon paper, carbon cloth, or carbon felt, and has gas diffusibility. Tin oxide or titanium oxide can also be used as the carrier of the reaction layer 11.
The electrolyte can be arbitrarily selected as long as it allows proton movement, but Nafion is preferably used from the standpoint of durability and the like.
The reaction layer 11 is laminated on the diffusion layer 16 by applying a paste of catalyst and electrolyte constituting the reaction layer 11 to the diffusion layer 16 and drying. Such a laminate is bonded to the solid electrolyte membrane 2.
The air electrode 20 includes a reaction layer 21 and a diffusion layer 26. The basic structure and manufacturing method of the reaction layer 21 and the diffusion layer 26 are the same as those of the hydrogen electrode 10.
However, since the fuel cell reaction is performed exclusively in the reaction layer 21 of the air electrode 20, the reaction layer 21 determines the characteristics of the fuel cell 1.

The inventor has proposed a PFF structure as the reaction layer. In the present invention, a method for producing a catalyst suitable for the PFF structure is proposed.
The PFF structure will be described.
Here, the PFF (Applicant's registered trademark) structure refers to a structure in which the hydrophilic functional group of the side chain of the polymer electrolyte is oriented to the catalyst side so as to form a hydrophilic layer on the catalyst.
For example, in perfluorosulfonic acid (Nafion, etc .; registered trademark of DuPont) widely used as a polymer electrolyte, a sulfone group (SO ₃ ⁻ ) as a hydrophilic functional group is present in the side chain E2 with respect to the hydrophobic main chain E1. As shown in FIG. 2, this hydrophilic functional group is oriented toward the catalyst C, whereby a continuous hydrophilic region W is formed between the catalyst C and the electrolyte layer E. In the agglomerated catalyst C, the hydrophilic regions W on the surfaces of the catalyst particles communicate with each other. Proton (H ⁺ ) and water (H ₂ O) can move smoothly in the hydrophilic region W of the PFF structure, and as a result, the electrochemical reaction of the fuel cell is promoted.
In addition, according to the PFF structure, since water is gathered around the catalyst C, most of the water efficiently contributes to the electrochemical reaction even in a small amount of water. Capability can be prevented from decreasing. On the other hand, the continuous hydrophilic region W functions as a drainage path for excess water, and can prevent flooding even in a highly humidified state.

In the above description, the catalyst C is a catalyst in which the catalyst metal particles C2 are supported on the carrier C1 having conductivity. The carrier C1 is required to have electrical conductivity and air permeability, and porous carbon black particles can be used, but tin oxide, titanic acid compounds, and the like can also be used. The catalytic metal particles C2 are made of fine metal particles that can provide an active site for the fuel cell reaction, and a noble metal such as platinum, cobalt, ruthenium, and an alloy of the noble metal can be used.
The method of supporting the catalyst metal particles C2 on the support C1 can be appropriately selected from known methods such as an impregnation method, a colloid method, and a precipitation-precipitation method depending on the material of both and the use of the catalyst.

(Catalyst treatment)
Usually the catalyst is provided by the catalyst manufacturer. It is preferable to physically and / or chemically treat the catalyst according to the characteristics required for the fuel cell.
(Physical treatment of catalyst)
The physical treatment of the catalyst includes a pulverization treatment and a defoaming treatment.
-Grinding treatment-
In general, in a catalyst, carriers are aggregated to form secondary particles and tertiary particles. Therefore, in order to improve the surface area of the catalyst, it is preferable to pulverize the agglomerates into a fine powder. For this purpose, it is preferable to disperse the agglomerates of the catalyst in a medium and perform wet pulverization.
By adopting wet pulverization, it becomes possible to pulverize the catalyst aggregate more finely by applying higher energy to the agglomerates of the catalyst as compared with dry pulverization. In addition, recombination of the catalyst can be effectively prevented as compared with dry pulverization. As a wet pulverization method, a homogenizer, a wet jet mill, a ball mill or a bead mill can be employed.
By adopting wet pulverization, an effect of removing impurities adhering to the catalyst carrier can be obtained. Usually, water is used as the medium, but other medium (organic solvent or the like) may be used depending on the characteristics of the impurities. It is also possible to first perform wet pulverization using water as a medium, and then remove impurities from the catalyst with an organic solvent or the like.
In order to dry the wet pulverized catalyst, it is preferable to remove the medium by sublimation. Thereby, reaggregation of the catalyst can be prevented. An example of a method for sublimating the medium is a vacuum drying method. On the other hand, when the heat drying method is adopted, when the medium is moved by heating or when the medium evaporates, a capillary contraction phenomenon occurs and the catalysts recombine, and the high dispersion state obtained by wet drying is obtained. It cannot be maintained.
The wet pulverization and, if necessary, impurity removal may be performed on the catalyst support, and the catalyst metal particles may be supported on the support in a state where the support is dispersed in a medium (for example, water). Even in this case, as a drying step, it is preferable to remove the medium in which the catalyst is dispersed by sublimation.

-Defoaming treatment-
It is necessary to remove bubbles (defoaming treatment) from around the catalyst in a state where the catalyst is mixed and dispersed in water. This is because the bubbles obstruct the formation of the hydrophilic region between the catalyst and the electrolyte layer.
This defoaming treatment can be performed by using a centrifugal stirring method with a hybrid mixer (rotating / revolving centrifugal stirrer).
Of course, the present invention is not limited to the centrifugal stirring method, and other stirring methods (ball mill method, stirrer method, bead mill method, roll mill method, etc.) can also be used.
In some cases, bubbles may be removed from around the catalyst during wet pulverization, in which case independent defoaming treatment is unnecessary.

(Chemical treatment of catalyst)
The catalyst is chemically treated to modify the surface of the catalyst metal particles with specific hydrophilic groups.
By modifying the surface of the metal catalyst particles with a hydrophilic group, the hydrophilicity around the catalyst metal particles is improved, and the hydrophilicity of the hydrophilic region W between the catalyst C and the electrolyte layer E is increased.
Here, the modification means that the modifying group is present on the surface of the catalytic metal particle, and the modifying group is not separated from the catalytic metal particle even through a normal production process.
Examples of the hydrophilic group include at least one selected from a nitrate group, an amino group, a sulfonic acid group, a hydroxyl group, and a halogen group. More preferably, at least one selected from a nitric acid group, an amino group, and a sulfonic acid group can be given as a hydrophilic group.
The presence of these hydrophilic groups around the catalyst metal particles makes it easy to form a hydrophilic region around the catalyst metal particles. Since the catalyst metal particles are evenly dispersed in the support, as a result, a hydrophilic region on the surface of the catalyst is likely to be formed, and it is stabilized after the formation.
As a method of modifying the above-mentioned hydrophilic group on the catalyst metal particles, in the present invention, a complex of a metal (noble metal) that is the same as or the same type as the catalyst metal particles and includes the modification group is bonded to the catalyst metal particles. By using the complex, the hydrophilic group can be modified to the catalytic metal particles without any stress on the structure of the catalyst.

When platinum or a platinum alloy is employed as the catalyst metal particles, the modification is preferably performed with the following platinum complex solution. As such a platinum complex solution, a platinum chloride (IV) acid hydrate aqueous solution (H ₂ PtCl ₆ .nH ₂ O / H ₂ O sol.), A platinum chloride (IV) hydrochloride acid solution (H ₂ PtCl ₆ / HCl sol. ), Platinum chloride (IV) ammonium aqueous solution ((NH ₄ ) ₂ PtCl ₆ / H ₂ O sol.), Dinitrodiammine platinum (II) aqueous solution (cis- [Pt (NH ₃ ) ₂ (NO ₂ ) ₂ ] / H ₂ O sol.), Dinitrodiammine platinum (II) nitric acid solution (cis- [Pt (NH ₃ ) ₂ (NO ₂ ) ₂ ] / HNO ₃ sol.), Dinitrodiammine platinum (II) sulfuric acid solution (cis- [ Pt (NH ₃ ) ₂ (NO ₂ ) ₂ ] / H ₂ SO ₄ sol.), Potassium tetracurl platinum (II) acid aqueous solution (K ₂ PtCl ₄ ) / H ₂ O sol. ), Platinum (II) chloride aqueous solution (PtCl ₂ / H ₂ O sol.), Aqueous platinum (IV) chloride (PtCl ₄ / H ₂ O sol.), Tetraammineplatinum (II) dichloride hydrate aqueous solution ([Pt (NH ₃ ) ₄ ] Cl ₂ .H ₂ O / H ₂ O sol.), Tetraammineplatinum (II) hydroxide aqueous solution ([Pt (NH ₃ ) ₄ ] (OH) ₂ / H ₂ O sol. .), Hexaammine platinum (IV) dichloride aqueous solution ([Pt (NH ₃ ) ₆ ] Cl ₂ / H ₂ O sol.), Hexaammine platinum (IV) hydroxide aqueous solution ([Pt (NH ₃ ) ₆ ] ( OH) ₂ / H ₂ O sol.), Hexahydroxoplatinum (IV) acid aqueous solution (H ₂ [Pt (OH) ₆ ] / H ₂ O sol.), Hexahydroxoplatinum (IV) acid nitric acid solution (H ₂ [ _{Pt (OH) 6] / HNO} 3 sol.), hexahydro Seo platinum (IV) acid sulfuric acid solution _{(H 2 [Pt (OH)} 6] / H 2 SO 4 sol.), Ethanolamine platinum solution _{(H 2 [Pt (OH)} 6] / H 2 NCH 2 CH 2 OH sol .) Etc. can be adopted.

According to the inventor's knowledge, it is preferable to select a nitrate group as a hydrophilic group for modifying the catalytic metal particles made of platinum or a platinum alloy. Nitroplatinum complex solution for that purpose includes dinitrodiammineplatinum (II) nitric acid solution (cis- [Pt (NH ₃ ) ₂ (NO ₂ ) ₂ ] / HNO ₃ sol.), NO ₃ ⁻ as a hydrophilic ion, hexa hydroxo Pt (IV) acid nitric acid solution _{((H 2 Pt (OH)} 6) / HNO 3 sol.), hexahydroxoplatinate and SO ₄ ^{2-hydrophilic} ion source platinum (IV) acid sulfate solution ((H ₂ Pt ( _{OH) 6) / H 2 SO} 4 sol.), tetraammineplatinum (II) hydroxide aqueous solution of NH ₄ ⁺ and hydrophilic ion _{([Pt (NH 3) 4} (OH) 2] / H 2 O sln. ) Etc. can be employed.

  The method of modifying the hydrophilic group on the catalyst metal particles can be appropriately selected according to the characteristics of the catalyst metal particles and the hydrophilic group. For example, when the catalyst metal particles are made of platinum or a platinum alloy, the catalyst is treated with a platinum complex solution. And may be stirred if necessary. When a nitric acid group is selected, the raw material catalyst is put into an aqueous nitric acid solution of dinitrodiamine platinum (complex) and stirred to adsorb the platinum complex (dinitrodiamine platinum) to the catalyst platinum particles of the raw material catalyst. Further, a nitric acid aqueous solution of dinitrodiamine platinum (complex) may be added and stirred in a state where the raw material catalyst is dispersed in water. Here, the stirring is not limited to mechanical stirring using a blade or a stirrer, and can be performed by circulating two solutions through one pipe line.

(Physical and chemical treatment order for catalyst)
In order to efficiently modify the catalytic metal particles in the catalyst with a hydrophilic group, it is preferable to perform physical treatment prior to chemical treatment. This is because, by physically treating the catalyst, more catalyst metal particles can come into contact with the treatment liquid containing a hydrophilic group. In a fuel cell including a catalyst obtained by performing physical treatment (particularly wet pulverization) prior to chemical treatment, temperature characteristics are improved as compared with a fuel cell provided with a catalyst that does not perform such treatment. That is, the output at the same temperature is improved, and furthermore, power generation at a higher temperature is possible.
In addition, when there exists a possibility that a catalyst may re-aggregate by a chemical process, it is preferable to perform a physical process again after performing a chemical process.
Of course, the chemical treatment for the catalyst may be performed first, followed by the physical treatment.
In order to obtain a PFF structure, it is necessary to perform a defoaming process on at least the catalyst.

(Pre-paste preparation)
The water content is adjusted in a pre-paste obtained by dispersing the catalyst in water.
In order to obtain a hydrophilic region between the electrolyte and the catalyst by causing the hydrophilic group of the electrolyte to face the surface of the catalyst, the catalyst and water are mixed to form a water layer in advance on the surface of the catalyst (catalyst hydrophilicity). Process).
According to the study of the present inventor, the mixing ratio of the catalyst and water should be appropriately selected according to the type of catalyst (especially the type of catalyst carrier and the particle size), but the mixture of catalyst and water ( Moisture state (flowability limit) where the pre-paste changes from a capillary state (water is present around the catalyst particles but no fluidity) to a slurry state (water is present around the catalyst particles and fluidity) ) And the moisture state in the vicinity thereof. Such an amount of water is an optimum amount capable of forming a continuous hydrophilic region between the catalyst and the electrolyte while making the surface of the catalyst hydrophilic.
Here, the flow limit refers to the limit of the moisture content at which the mixture changes from the capillary state to the slurry state and begins to flow.

In the relationship between the shear rate and the viscosity of the pre-paste, the flow limit is a paste state in which the slope of the approximate line is −1 when the approximate straight line is obtained by plotting the viscosity with logarithm against the shear rate. The slurry state is a paste state in which the slope of the approximate straight line is −0.8.
The slope of the approximate straight line in the relationship of the viscosity to the shear rate is −1 or more, that is, the slope becomes gentle and the slurry state becomes highly fluid. Since the state containing excessive moisture leads to a decrease in MEA performance, the amount of water added in a range from the flow limit to the slurry state, that is, in the range of slope −1 to −0.8, is the optimum amount. Thereby, an ideal pre-paste can be obtained. In the pre-paste, it is important to define the minimum amount of water added based on the slope of this approximate line. On the other hand, in the capillary state where the inclination is less than -1 (the inclination becomes tight), the fluidity of the mixture is lost, so that more energy is required at the time of mixing, and the stirring of water and the catalyst tends to be insufficient, and a suitable pre-paste Is not suitable as a condition for obtaining.

Even when the amount of water is greater than the optimum amount, water exists around the catalyst, so that the surface of the catalyst can be hydrophilized. However, such excessive moisture may interfere with the construction of the PFF structure when the pre-paste is mixed with the electrolyte solution (pre-solution). Excess water leaves the catalyst and attracts the electrolyte's hydrophilic groups in a region away from the catalyst. Therefore, the hydrophilic group of the electrolyte facing the catalyst is reduced, and as a result, the hydrophilic region to be formed between the catalyst and the electrolyte is narrowed or divided, and the hydrophilic function in the region is reduced ( Decrease in water retention).
When the catalyst is wet pulverized in water, the catalyst is dispersed in a large amount of water. Here, the amount of water is preferably 5 to 100 in weight ratio to the catalyst. Thereafter, the water is removed to obtain a water content suitable for the pre-paste. For removing water, a method such as hot water bathing can be employed.

(Preparation of electrolyte solution)
As the electrolyte, the above-mentioned perfluorosulfonic acid is generally used. This electrolyte is dissolved in a mixed solvent of water and an organic solvent and mixed with the above-described pre-paste.
The organic solvent is appropriately selected according to the characteristics of the electrolyte, but according to the study of the present inventor, the organic solvent is preferably at least one of a secondary alcohol and a tertiary alcohol. With primary alcohols such as methanol and ethanol, the viscosity of the electrolyte solution does not increase even when the water concentration is reduced. If a secondary alcohol such as isopropyl alcohol (IPA) or a tertiary alcohol such as tertiary butyl alcohol (TBA) is mixed, the solid content of the electrolyte in the electrolyte solution is more undissolved. Further, according to the inventor's study, when the secondary alcohol and the tertiary alcohol are mixed, the solid content of the electrolyte in the electrolyte solution is further unraveled.
As a result of studying optimization of the electrolyte solution used in the above-described PFF structure, the present inventor has found that the optimal amount of water to be contained in the electrolyte solution is 10% by weight or less, more preferably 5% by weight or less of the electrolyte solution. I realized that there was.

There is the following relationship between the electrolyte and the amount of water.
It has been found that when the concentration of water in the electrolyte solution is reduced, the viscosity of the electrolyte solution increases even when the concentration of the electrolyte in the electrolyte solution is the same. Conversely, when the concentration of water is increased, the viscosity of the electrolyte solution decreases. . The reason is estimated as follows.
That is, when the concentration of water in the electrolyte solution is high, as shown in FIG. 3A, water is adsorbed on the side chain E2 of the electrolyte, the main chain E1 of the electrolyte contracts in the electrolyte solution, and the electrolyte is separated. It was assumed that the viscosity of the electrolyte solution was lowered. Further, when the water concentration of the electrolyte solution becomes slightly low, the main chain E1 of the electrolyte opens in the electrolyte solution as shown in FIG. 3B due to the action of the organic solvent contained in the electrolyte solution. As a result, the viscosity of the electrolyte solution increases.

When a reaction layer is formed by mixing the electrolyte solution in the state of the electrolyte (A in FIG. 3), it is considered that this reaction layer is in a state as shown in FIG. That is, since the main chain of the electrolyte is shrunk and the electrolytes are separated from each other, when this is mixed with the pre-paste, there is a high possibility that the hydrophilic region W is formed in a dispersed manner.
In other words, in order to make the hydrophilic side chain E2 of the electrolyte face the catalyst and to reliably form a hydrophilic region between the two, the electrolyte is in the state of FIG. 3B in the electrolyte solution. It is preferable to do. For this purpose, as described above, the amount of water contained in the electrolyte solution is set to 10% by weight or less of the electrolyte solution.

The cathode catalyst layer when the electrolyte in the state shown in FIG. 3B is used is considered to be in the state shown in FIG.
The side chain E2 of the electrolyte is in a state extending in one direction. Therefore, in the catalyst paste, that is, the fuel cell reaction layer, hydrophilic ion exchange groups (sulfone groups) adsorb water in the pre-paste. Become. For this reason, as shown in FIG. 2, in this reaction layer, the electrolyte hydrophilic group E <b> 2 faces the surface of the catalyst C, and a hydrophilic region W is formed between the electrolyte layer E and the catalyst C. And it is thought that the hydrophilic region W is continuously formed around the catalyst C and is formed in a state of communicating with each other by adsorbing the sulfone group with the water in the pre-paste as described above. For this reason, in the reaction layer using this catalyst paste, as shown in FIG. 2, protons and water easily move, and the electrochemical reaction proceeds smoothly. A fuel cell having such a reaction layer can have a high power generation capacity regardless of whether it is in a low humidified state or an excessively humidified state.

The amount of water in the electrolyte solution is determined by evaporating water from the electrolyte solution using, for example, a hot water bath, and then adding water appropriately.
When water is evaporated from the electrolyte solution, the organic solvent contained in the electrolyte solution is also volatilized. Accordingly, an organic solvent is also added as necessary.

(Mixing of pre-paste and electrolyte solution)
A catalyst paste is obtained by mixing the pre-paste and the electrolyte solution.
The pre-paste prepared as described above has a high viscosity because it is in the vicinity of the fluidity limit. The viscosity of the electrolyte solution increases as the amount of water contained therein decreases.
In any case, when the pre-paste obtained under the condition of increasing the viscosity and the electrolyte solution are mixed and stirred, as shown in FIG. 5 (A), the viscosity of the mixture decreases with time, and then stabilizes at a constant value. .

The inventor paid attention to the behavior of the viscosity of the mixture when the mixture of the pre-paste and the electrolyte solution was stirred.
FIG. 5B shows the relationship between the stirring time (= viscosity) and the reaction layer resistance.
A fuel cell was constructed using the catalyst paste obtained by changing the stirring time (= viscosity), and the impedance of the reaction layer was measured.
5A and 5B, it can be seen that when the viscosity decreases with stirring, the impedance of the reaction layer increases so as to be inversely proportional thereto. An increase in impedance means a decrease in proton movement in the reaction layer.

From the above, when preparing the catalyst paste by mixing the pre-paste and the electrolyte solution, it is preferable to quickly stir and complete the uniform mixing of both before the viscosity of the mixture decreases and stabilizes. Recognize. In other words, when the pre-paste and the electrolyte solution are agitated, the viscosity of the mixture of both is monitored, and the agitation is stopped before the viscosity stabilizes to a low level.
When the mixture of the pre-paste and the electrolyte solution is stirred, the periphery of the catalyst of the pre-paste is covered with the electrolyte. At this time, the electrolyte in an open state as shown in FIG. 3B is oriented with its hydrophilic group facing the catalyst to construct a PFF structure. However, if stirring is performed after the PFF structure is constructed (hereinafter sometimes referred to as “over-stirring”), the electrolyte facing the catalyst is separated from the catalyst, and then water on the catalyst surface is taken away from the catalyst surface. break away. Since the electrolyte separated from the catalyst surface is accompanied by water on the catalyst surface, the electrolyte easily takes the form of FIG. Therefore, it is considered that the viscosity of the electrolyte solution component in the catalyst paste decreases, which causes a decrease in the viscosity of the catalyst paste itself. Also, the PFF structure becomes brittle when the electrolyte is detached from the catalyst surface, and the function of the hydrophilic region formed between the catalyst and the electrolyte is lowered. This is expected to increase the reaction layer resistance.
Therefore, the viscosity of the mixture of the pre-paste and the electrolyte solution is adjusted to a predetermined viscosity. Thereby, both over-stirring can be prevented. That is, the over-stirred mixture lowers its viscosity as described above, so that it is possible to prevent over-stirring of the mixture by stopping stirring when the viscosity of the mixture exhibits a predetermined behavior. By preventing over-stirring, a stable PFF structure can always be constructed.

A rotating / revolving centrifugal stirrer is preferably used for mixing and stirring the pre-paste and the electrolyte solution, but a general ball mill, bead mill, stirrer, homogenizer, or the like having a mixing and stirring function can also be employed.
The viscosity of the mixture of the pre-paste and the electrolyte solution varies depending on each material, the blending ratio, the environmental temperature, and the like. Therefore, the viscosity of the mixture is monitored and its behavior (not the absolute value of the viscosity) is detected and evaluated.
The behavior of the viscosity of the mixture refers to the change in viscosity over time before the viscosity of the mixture is stabilized to a low level. For example, the rate of decrease in viscosity per unit time or the rate of decrease in viscosity with respect to the initial viscosity can be employed.
As is clear from FIG. 5A, when the stirring of the mixture exceeds a certain time (4 minutes in the example of FIG. 5A), the rate of decrease in viscosity per time increases. Therefore, stirring can be stopped when the rate of decrease in the viscosity of the mixture accompanying stirring exceeds a predetermined value.
In order to manage the viscosity in the process of producing the catalyst paste, it is preferable to keep the rotation speed of the hybrid mixer constant. Furthermore, it is preferable to perform stirring at a constant temperature.
In order to more accurately manage the viscosity, the viscosity of the mixture can be measured in real time during stirring. For example, the mixing of the pre-paste and the electrolyte solution and the viscosity measurement can be simultaneously performed using a rotor rotation control viscometer. In addition, a method of using a bead mill, a homogenizer, or the like for mixing the pre-paste and the electrolyte solution and incorporating a viscometer capable of real-time measurement such as a tuning fork type vibration viscometer into the paste circulation line is also applicable.
In any method, it is preferable to perform stirring and viscosity measurement at a constant temperature.

(Formation of reaction layer)
The catalyst paste obtained as described above is applied to a gas diffusion substrate to form a reaction layer. Carbon cloth, carbon paper, carbon felt, etc. can be adopted as the gas diffusion base material. It is preferable to form a water repellent layer on the surface (reaction layer side surface) of the gas diffusion substrate. This water repellent layer can be formed from carbon black treated with water repellent with PTFE, for example. As a method for applying the catalyst paste, any method such as screen printing, spraying or ink jetting can be adopted.
In the above, the reaction layer using the catalyst paste having a low viscosity can be provided in a portion where the electrode is easily flooded, for example, in the vicinity of the air outlet, in the vicinity of the hydrogen outlet, in the outer periphery of the electrode, in the vicinity of the cooling plate. As a result, high performance is stably exhibited even in a high humidity atmosphere.
Further, a reaction layer using a high-viscosity catalyst paste may be provided in a portion where the electrode is easily dried, for example, in the vicinity of the air inlet, in the vicinity of the hydrogen inlet, in the center of the electrode, or in a portion away from the cooling plate. As a result, high performance is stably exhibited even in a low humidified atmosphere.
By applying and drying the catalyst paste on the gas diffusion base material a predetermined number of times, an air electrode (gas diffusion base material + reaction layer) and a hydrogen electrode (gas diffusion base material + reaction layer) are formed. A membrane electrode assembly (MEA) is obtained by sandwiching a polymer electrolyte membrane between the air electrode and the hydrogen electrode and joining them by hot pressing or the like. The membrane electrode stack is sandwiched between separators to constitute a fuel cell that is a minimum power generation unit.

In the above, the manufacturing method and the material used for manufacture of a catalyst paste have been demonstrated exclusively.
FIG. 6 is a block diagram showing an apparatus for producing a catalyst paste.
The catalyst, water, noble metal complex, and electrolyte that are the raw materials of the catalyst paste are prepared in the catalyst storage unit 1001, the water storage unit 1021, the noble metal complex solution storage unit 1025, and the electrolyte solution storage unit 1041, respectively. Note that an organic solvent for cleaning organic substances from the catalyst is prepared in the organic solvent container 1023. A tank formed of a capacity and a material corresponding to the object to be accommodated can be used as each accommodating part.
The catalyst processing unit 1003 includes a physical processing unit 1005 and a chemical processing unit 1007. The physical processing unit 1005 includes a wet pulverization unit 1009 and a defoaming unit 1011. A homogenizer, a wet jet mill, or the like can be used as the wet pulverization unit 1009. A hybrid mixer or the like can be used for the defoaming portion 1011. The chemical processing unit 1007 can be a general-purpose stirring device provided with stirring blades. When a noble metal complex having high reactivity with the metal catalyst particles is employed, it is possible to complete the chemical reaction by injecting the noble metal complex solution into a conduit through which the catalyst slurry flows.

In the catalyst processing unit, the catalyst is dispersed in a large amount of water to form a slurry-like pre-paste. Therefore, the water content adjusting unit 1031 adjusts the water content of the pre-paste.
In this case, since moisture is removed from the slurry-like pre-paste, a well-known concentration method (for example, a heating evaporation device, a filtration device, or a centrifuge device) can be used. Moreover, since the water content can be specified from the specific gravity of the pre-paste, the water content adjusting unit preferably includes a specific gravity measuring device. In addition, assuming that the moisture content of the pre-paste becomes too small, it is preferable to provide a moisture supply device.

The electrolyte solution moisture adjusting unit 1043 preferably includes a heating evaporation device and a moisture replenishing device. Since the water content can be specified from the specific gravity, it is preferable to further include a specific gravity measuring device.
The mixing and stirring unit 1051 mixes and stirs the pre-paste and the electrolyte solution each having a controlled amount of water. For example, a hybrid mixer can be used, but is not limited thereto. In order to avoid over-stirring, it is preferable to attach a viscometer 1061 to the mixing and stirring unit 1051.

<Details of Embodiment of the Invention>
In the above, the invention proposed in this application is such that the chemical treatment of the catalyst can be continuously performed.
In the present invention, the catalyst metal particles are modified with a hydrophilic group by using as a reactor a pipeline for conveying the raw material catalyst slurry in which the raw material catalyst is dispersed in water.
FIG. 7 shows a flow of a method for producing the catalyst paste of the embodiment.
In step a-1, a catalyst slurry in the vicinity of the flow limit is prepared. Here, the catalyst is obtained by supporting platinum fine particles on carbon black.
In step a-2, centrifugal stirring is performed by a hybrid mixer. Water is added to the centrifugally stirred catalyst slurry to adjust the amount of water (step a-3), which is suitable for the wet pulverization executed in step a-4. A homogenizer is selected as the wet pulverization apparatus, and the catalyst is pulverized until the particle size of 10 μm or more in the catalyst slurry is 1% or less.

In step b-1, a nitric acid solution of hexahydroxoplatinic acid is added to and mixed with the wet-pulverized catalyst slurry, and the platinum fine particles of the catalyst are modified with nitrate groups. The method is shown in FIG.
In FIG. 8, reference numeral 31 denotes a pipe line, and the wet-pulverized catalyst slurry is introduced into the pipe line 31 by a pump 33. The length, inner diameter, and material of the pipe line 31 are appropriately selected according to the discharge pressure of the pump 33, the viscosity of the catalyst slurry, and the like.
An injection pipe 35 is branched from the pipe line 31, and the injection pipe 35 communicates with a water tank 38 via a pump 37. A syringe pump 39 is attached to the injection pipe 35 immediately before being connected to the pipe line 31, and a 50% nitric acid solution of hexahydroxoplatinic acid is added to the injection pipe 35 by the syringe pump 39. Nitrate 50% solution of injected into the injection tube 35 hexahydroxoplatinum acid is diluted with water flowing through the injection pipe 35 is injected into the conduit 35.
Here the degree of dilution of nitric acid 50% solution of hexahydroxoplatinum acid is appropriately adjusted according to the flow rate of the catalyst slurry concentration and pipe 31 of the catalyst in the catalyst slurry and the like.
For example, in this example, the 50% nitric acid 50% solution is 0.3 to 0.5% solution, that is, the 50% nitric acid solution is 0.3 to 0.5% by volume with respect to the water 100 flowing through the injection pipe 35. Inject 0.5%. On the other hand, in the catalyst slurry, 0.5 to 1.0 part by weight of the catalyst is dispersed with respect to 100 parts by weight of water. After the diluted nitric acid solution of hexahydroxyplatinic acid is injected from the injection pipe 35, it is allowed to stay in the pipe 31 for 20 to 30 seconds to promote the reaction with the platinum fine particles of the catalyst.
In order to promote mixing of the catalyst and the nitric acid solution, it is preferable to fill the inside of the pipe 31 with the catalyst slurry so that no air layer exists in the pipe 31. Moreover, in order to promote mixing of the catalyst and the nitric acid solution, spiral grooves and / or ridges can be provided in the pipe 31. Furthermore, the pump 33 may be operated intermittently.

After the platinum fine particles of the catalyst are modified with nitrate groups, moisture adjustment is performed (step a-5). Specifically, as shown in FIG. 8, the slurry is allowed to stand to precipitate the catalyst, and then the supernatant liquid is removed, and further water is removed to remove water.
By this moisture adjustment, moisture is reduced from the catalyst slurry, so that the moisture content (near the flow limit) is suitable as a pre-paste. The pre-paste is centrifugally stirred by a hybrid mixer (step a-6), an electrolyte solution is further added (step a-7), and centrifugal stirring is performed while monitoring the viscosity by the hybrid mixer (step a-8, ) To obtain a catalyst paste.

FIG. 9 shows a flow of a method for producing a catalyst paste according to another embodiment. 9, the same processes as those in FIG. 7 are denoted by the same reference numerals, and the description thereof is omitted.
In the example of FIG. 9, a nitric acid solution of hexahydroxoplatinic acid is added and mixed between centrifugal stirring (step a-2) and (water amount adjustment) step a-3. In this example, the nitrate 31 is not modified to the platinum fine particles using the conduit 31 shown in FIG. 8, but is added to the slurry to be wet crushed, and the nitrate groups are modified to the platinum fine particles at the time of wet pulverization. To do. Here, it is preferable to dilute the nitric acid solution with water immediately before mixing into the slurry and add it to the slurry.
By adopting such a method, an apparatus for mixing the catalyst slurry and the hexahydroxoplatinic acid nitric acid solution as shown in FIG. 8 becomes unnecessary. Therefore, not only the apparatus can be simplified, but also the independent mixing step is omitted, so that the manufacturing cost can be reduced by shortening the process.

The following test examples of the present invention will be described.
(Test Example 1)
A carbon-supported platinum catalyst was prepared as a raw material catalyst. This raw material catalyst has carbon black particles as a carrier and catalyst platinum particles supported thereon by a well-known method (supported amount: 50%).
On the other hand, 1 g of a raw material catalyst is charged into a nitric acid solution of hexahydroxoplatinum (IV) acid (Pt 0.05 g / 150 ml) and a nitric acid concentration of 0.3%, and stirred with a stirrer at room temperature for 5 hours. Then, it applied to the homogenizer. The wet pulverized slurry is filtered and dried in vacuum at 60 ° C. for 2 hours. Further, heat treatment is performed at 150 ° C. for 2 hours in a nitrogen atmosphere.
The XPS of the obtained sample (Example 1) is shown in FIG. Comparative Example 1 is a reaction layer prepared under the same conditions as in Test Example 1 except for the modification step of the sulfonic acid group.
From the results of FIG. 10, it can be seen that many sulfonic acid groups are present around the catalytic metal particles subjected to the above treatment.

The catalyst treated as described above becomes a reaction layer constituting a PFF structure. The characteristics of such a reaction layer are shown in FIG.
In Comparative Example 2, the amount of catalyst platinum particles supported in the raw material catalyst is four times that in Test Example 1 and Comparative Example 1 (the preparation conditions are the same as those in Comparative Example 1).
In FIG. 11, the air supplied to the air electrode side of the fuel cell is fully humidified at 60 ° C. Thus, when the cell temperature is higher than 60 ° C., the fuel cell is in a dry condition. Therefore, the result of FIG. 11 shows the performance of the fuel cell in a low humidified environment.
From the results of FIG. 11, in the fuel cell provided with the reaction layer obtained by the manufacturing method of Test Example 1, even if the amount of catalyst platinum particles supported is reduced to about ¼, the function of the fuel cell is not deteriorated. I understand that.

Example 1
In Example 1, the stirrer stirring for 5 hours was omitted in Test Example 1 above, and 1 g of raw material catalyst was added to a nitric acid aqueous solution of hexahydroxoplatinum (IV) acid (Pt 0.05 g / 150 ml) and a nitric acid concentration of 0.3%. The product was directly homogenized. The time required for homogenizing was 10 minutes.
The characteristics of the obtained reaction layer are shown in FIG. In FIG. 12, the air supplied to the air electrode side of the fuel cell is fully humidified at 60.degree.
From the results of FIG. 12, it can be seen that the nitric acid solution of hexahydroxoplatinic acid is highly reactive with the platinum fine particles of the catalyst, and the platinum fine particles are modified with nitrate groups in a short time.

Next, another test example of the present invention will be described.
In this test example, in the method shown in FIG. 7, the hexahydroxoplatinic acid charging and stirring step b-1 is performed without using the stirring device shown in FIG. Hexahydroxoplatinic acid was charged into the container at the same ratio as in FIG. 9, the amount of water was adjusted (step a-5), and stirred (step a-6).
The temperature characteristics of the fuel cell formed by the catalyst paste thus obtained (Example 2) and the temperature characteristics of the fuel cell formed by the catalyst paste obtained by the method of FIG. 9 (Reference Example 2) As shown in FIG.
The operating conditions of the fuel cell when the results of FIG. 13 are obtained are as follows.
Load: 1.6 A / cm ² (const.)
Humidification temperature: 60 ° C
Hydrogen supply rate: 0.8L / min (0.1MPa-G)
Air supply rate: 3L / min (0.1MPa-G)
Electrode area: 20.25 cm ²
Platinum loading: 0.3 mg / cm ²

  From the results shown in FIG. 13, when the catalyst is wet pulverized and then hexahydroxoplatinic acid is adsorbed to the platinum particles, in other words, when chemical treatment is performed after wet pulverization of the catalyst, the temperature characteristics of a fuel cell including such a catalyst Can be seen to improve. That is, the catalyst obtained by chemical treatment after wet pulverization improves the output at the same temperature in the temperature characteristics of the fuel cell compared to the catalyst obtained by wet pulverization after chemical treatment of the catalyst, and , Improve the maximum output temperature.

  The present invention is not limited to the description of the embodiments and examples of the invention described above. Various modifications are also included in the present invention as long as those skilled in the art can easily conceive without departing from the scope of the claims.

DESCRIPTION OF SYMBOLS 1 Fuel cell, 2 Solid electrolyte membrane, 10 Hydrogen electrode, 11 Reaction layer, 16 Diffusion layer, 20 Air electrode, 21 Reaction layer, 31 Pipe line, 33, 37 Pump, 35 Injection pipe, 38 Water tank, 39 Syringe pump C Catalyst, C1 carrier, C2 catalyst metal particle E electrolyte layer, E1 main chain, E2 side chain W hydrophilic region

Claims (4)

Provided with a chemical treatment unit for mixing an aqueous solution containing a hydrophilic group for modifying the catalytic metal particles with a raw material catalyst slurry obtained by mixing water with a raw material catalyst obtained by supporting catalytic metal particles on a carrier, and containing the hydrophilic group The aqueous solution is a hexahydroxoplatinic acid nitric acid aqueous solution,
The chemical treatment unit includes a conduit formed to a length that the hexahydroxoplatinic acid is adsorbed while the raw material catalyst slurry is conveyed, and an injection unit that injects an aqueous solution containing the hydrophilic group connected to the conduit. An apparatus for producing a catalyst for a fuel cell, comprising: 2. The apparatus for producing a fuel cell catalyst according to claim 1, wherein the catalytic metal particles are platinum or a platinum alloy, and the hydrophilic group is a nitrate group. The fuel cell for fuel cell according to claim 1 or 2, wherein a wet pulverization apparatus for wet pulverizing the raw material catalyst slurry introduced into the pipe line is disposed at the inlet of the pipe line . Catalyst production equipment. Claims wherein hexahydroxoplatinum acid is characterized in that, the moisture adjusting device for adjusting the water content of those discharged from the conduit a raw catalyst slurry adsorbed is arranged at the outlet of the conduit An apparatus for producing a fuel cell catalyst according to claim 1, claim 2 or claim 3.

Images