JPWO2019049755A1 - Carbon electrode material for redox flow battery and method for producing the same - Google Patents

Abstract

(EN) Provided is a carbon electrode material for a redox flow battery, which can reduce the cell resistance during initial charge and discharge and is excellent in battery energy efficiency. The electrode material of the present invention comprises a carbonaceous fiber (A) and a carbonaceous material (B) binding the carbonaceous fiber (A), and satisfies the following requirements. (1) When the crystallite size in the c-axis direction in the carbonaceous material (B) determined by X-ray diffraction is Lc(B), Lc(B) is less than 10 nm, and (2) carbonaceous fiber ( When the crystallite size in the c-axis direction determined by X-ray diffraction in A) is Lc(A), Lc(B)/Lc(A) is 1.0 or more, and (3) carbon electrode material surface The number of bonded oxygen atoms is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material.

Description

The present invention relates to a carbon electrode material used in a redox flow battery and a method for manufacturing the same, and more particularly to a carbon electrode material excellent in energy efficiency of the entire redox flow battery and a method for manufacturing the same.

A redox flow battery is a battery that uses redox ion redox in an aqueous solution, and is a very safe large-capacity storage battery because it is a mild reaction only in the liquid phase.

The main structure of the redox flow battery is, as shown in FIG. 1, composed of external tanks 6 and 7 for storing an electrolytic solution (a positive electrode electrolytic solution and a negative electrode electrolytic solution), and an electrolytic cell EC. In the electrolytic cell EC, the ion exchange membrane 3 is arranged between the current collector plates 1 and 1 facing each other. In the redox flow battery, while pumping the electrolyte solution containing the active material by the pumps 8 and 9 to the electrolytic cell EC from the external tanks 6 and 7, electrochemical energy conversion on the electrode 5 incorporated in the electrolytic cell EC, that is, Charge/discharge is performed. As the material of the electrode 5, a carbon material having chemical resistance, conductivity, and liquid permeability is used.

As an electrolytic solution used for a redox flow battery, an aqueous solution containing a metal ion whose valence changes by redox is typically used. The electrolytic solution has been increased in energy density by changing from a type using an aqueous hydrochloric acid solution of iron for the positive electrode and an aqueous hydrochloric acid solution of chromium for the negative electrode to a type using an aqueous sulfuric acid solution of vanadium with high electromotive force for both electrodes.

In the case of a redox flow battery using a sulfuric acid aqueous solution of vanadium oxysulfate as the positive electrode electrolyte and vanadium sulfate as the negative electrode electrolyte, during discharge, the electrolytic solution containing V ²⁺ is supplied to the liquid passage on the negative electrode side. An electrolyte solution containing V ⁵⁺ (actually oxygen-containing ions) is supplied to the side liquid passage. In the liquid passage on the negative electrode side, V ²⁺ emits electrons in the three-dimensional electrode and is oxidized to V ³⁺ . The emitted electrons pass through an external circuit and reduce V ⁵⁺ to V ⁴⁺ (actually an ion containing oxygen) in the three-dimensional electrode on the positive electrode side. Due to this oxidation-reduction reaction, SO ₄ ²⁻ in the negative electrode electrolyte becomes insufficient, and SO ₄ ²⁻ becomes excessive in the positive electrode electrolyte, so SO ₄ ²⁻ passes from the positive electrode side to the negative electrode side through the ion exchange membrane. And the charge balance is maintained. Alternatively, the charge balance can be maintained by moving H ⁺ from the negative electrode side to the positive electrode side through the ion exchange membrane. At the time of charging, the reaction opposite to that of discharging proceeds.

The following performances are particularly required for the electrode material for redox flow batteries.

1) No side reaction other than the intended reaction (high reaction selectivity), specifically, high current efficiency (η _I ).
2) High electrode reaction activity, specifically low cell resistance (R). That is, the voltage efficiency (η _V ) is high.
3) High battery energy efficiency (η _E ) related to 1) and 2) above.
η _E = η _I × η _V
4) Small deterioration due to repeated use (long life), specifically, a small decrease in battery energy efficiency (η _E ).

For example, Patent Document 1 discloses a carbonaceous material having a specific pseudo-graphite microcrystalline structure having high crystallinity as an electrode material for an Fe-Cr battery that can increase the total energy efficiency of the battery. Specifically, it has pseudo-graphite microcrystals having an average <002> plane spacing of 3.70 Å or less obtained by X-ray wide-angle analysis and a crystallite size in the c-axis direction of 9.0 Å or more on average. And a total amount of acidic functional groups of at least 0.01 meq/g is disclosed.

Patent Document 2 discloses a carbonaceous fiber made of polyacrylonitrile fiber as a raw material for an electric field layer electrode of an iron-chromium redox flow battery or the like which enhances energy efficiency of the battery and improves charge/discharge cycle life. Carbon composed of carbon having a pseudo-graphite crystal structure with a <002> plane spacing of 3.50 to 3.60Å obtained by line wide angle analysis, and the number of bonded oxygen atoms on the carbon surface is 10 to 25% of the number of carbon atoms. Electrode materials are disclosed.

Patent Document 3 discloses a carbon electrode material for a vanadium redox flow battery, which has excellent energy efficiency in the entire battery system and has little change in performance with long-term use, and has a <002> interplanar spacing determined by X-ray wide-angle analysis. It has a pseudo-graphite crystal structure of 3.43 to 3.60Å, the crystallite size in the c-axis direction is 15 to 33Å, and the crystallite size in the a-axis direction is 30 to 75Å, and has an XPS surface analysis. Disclosed is an electrode in which the amount of surface acidic functional groups obtained is 0.2 to 1.0% of the total number of surface carbon atoms and the number of surface-bound nitrogen atoms is 3% or less of the total number of surface carbon atoms.

Further, in Patent Document 4, as a carbon electrode material that enhances the overall efficiency of a vanadium redox flow battery and has a lower cell resistance at the time of initial charging, a crystal structure on a carbonaceous fiber was obtained by X-ray wide-angle analysis. 002> It consists of a carbon composite material with carbon fine particles having an interplanar spacing of 3.43 to 3.70Å and an average primary particle diameter of 30 nm or more and 5 μm or less. An electrode material having the obtained <002> plane spacing of 3.43 to 3.60Å, the crystallite size in the c-axis direction of 15 to 35Å, and the crystallite size in the a-axis direction of 30 to 75Å It is disclosed. In the above-mentioned carbon composite material, it is preferable that the carbonaceous fibers and the carbon fine particles are close to each other or adhered by an adhesive such as a phenol resin. By using the adhesive, carbon which is an electrochemical reaction field is formed. It is described that it is possible to fix only the portion that was originally in contact as the carbonaceous fiber without excessively reducing the surface of the quality fiber. In the section of Examples, carbonized after immersing the non-woven fabric in a solution containing 5% by weight of carbon fine particles (phenolic resin) (Example 1) or 5% by weight of phenolic resin (Examples 2 to 4), A carbonaceous fiber non-woven fabric obtained by dry oxidation treatment is disclosed.

Development of an electrolytic solution used for a redox flow battery has been ongoing since then, and as an electrolytic solution which has a higher electromotive force than the vanadium-based electrolytic solution described above and can be stably and inexpensively supplied, for example, Patent Document 5 As described above, the one using manganese for the positive electrode and chromium, vanadium, or titanium for the negative electrode (for example, Mn-Ti based electrolytic solution) has been proposed.

JP-A-60-232669 JP-A-5-234612 JP, 2000-357520, A JP, 2017-33758, A JP, 2012-204135, A

In order to promote the spread of redox flow batteries such as vanadium redox flow batteries, further low resistance and inexpensive electrode materials are required.

The present invention has been made in view of the above circumstances, and an object thereof is to provide a carbon electrode material for a redox flow battery, which can reduce the cell resistance at the time of initial charge/discharge and improve the battery energy efficiency.

The constitution of the carbon electrode material for a redox flow battery according to the present invention, which can solve the above problems, is as follows. In the present specification, the following 1 to 4 carbon electrode materials are first carbon electrode materials, the following 11 to 14 carbon electrode materials are second carbon electrode materials, and the following 21 to 24 carbon electrode materials are third carbon electrode materials. It may be called an electrode material.

(I) First carbon electrode material 1. A carbonaceous fiber (A) and a carbonaceous material (B) binding the carbonaceous fiber (A),
A carbon electrode material for redox flow batteries, which satisfies the following requirements.
(1) In the carbonaceous material (B), when the crystallite size in the c-axis direction obtained by X-ray diffraction is Lc(B), Lc(B) is less than 10 nm,
(2) When the crystallite size in the c-axis direction in the carbonaceous fiber (A) determined by X-ray diffraction is Lc(A), Lc(B)/Lc(A) is 1.0 or more,
(3) The number of bound oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. 2. The carbon electrode material according to 1 above, wherein the mass content of the carbonaceous material (B) is 14.5% or more based on the total amount of the carbonaceous fiber (A) and the carbonaceous material (B).
3. 3. The carbon electrode material as described in 1 or 2 above, wherein Lc(A) is 1 to 10 nm.
4. 4. The carbon electrode material as described in any one of 1 to 3 above, which has a water flow rate of 0.5 mm/sec or more when water drops are dropped.
5. A redox flow battery comprising the carbon electrode material according to any one of 1 to 4 above.
6. A vanadium redox flow battery using the carbon electrode material according to any one of 1 to 4 above.
7. A method for producing the carbon electrode material according to any one of 1 to 4 above,
Attaching the carbonaceous material (B) before carbonization to the carbonaceous fiber (A),
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order.

(II) Second carbon electrode material 11. A carbon electrode material for a redox flow battery, comprising a carbonaceous fiber (A), graphite particles (B), and a carbonaceous material (C) binding these, and satisfying the following requirements.
(1) When the size of the crystallite in the c-axis direction in the graphite particles (B) determined by X-ray diffraction is Lc(B), Lc(B) is less than 35 nm,
(2) When the size of the crystallite in the c-axis direction in the carbonaceous material (C) determined by X-ray diffraction is Lc(C), Lc(C) is less than 10 nm,
(3) When the crystallite size in the c-axis direction in the carbonaceous fiber (A) obtained by X-ray diffraction is Lc(A), Lc(C)/Lc(A) is 1.0 or more,
(4) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. The mass content of the carbonaceous material (C) with respect to the total amount of the carbonaceous fibers (A), the graphite particles (B), and the carbonaceous material (C) is 14.5% or more, and the graphite particles ( 12. The carbon electrode material as described in 11 above, wherein the mass ratio of the carbonaceous material (C) to B) is 0.2 to 3.0.
13. 13. The carbon electrode material as described in 11 or 12 above, which has a BET specific surface area determined from a nitrogen adsorption amount of more than 8 m ² /g.
14. The carbon electrode material as described in any one of 11 to 13 above, wherein a water flow rate when water drops are dropped is 0.5 mm/sec or more.
15. The redox flow battery provided with the carbon electrode material in any one of said 11-14.
16. A vanadium redox flow battery using the carbon electrode material according to any one of 11 to 14 above.
17. A method for producing the carbon electrode material according to any one of 11 to 14 above,
Attaching the graphite particles (B) and the carbonaceous material before carbonization (C) to the carbonaceous fibers (A);
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order.

(III) Third carbon electrode material 21. A carbonaceous fiber (A), carbon particles (B) other than graphite particles, and a carbonaceous material (C) binding these,
A carbon electrode material for redox flow batteries, which satisfies the following requirements.
(1) The particle size of the carbon particles (B) other than the graphite particles is 1 μm or less,
(2) In the carbon particles (B) other than the graphite particles, when the crystallite size in the c-axis direction obtained by X-ray diffraction is Lc(B), Lc(B) is 10 nm or less,
(3) When the crystallite sizes in the c-axis direction in the carbonaceous fiber (A) and the carbonaceous material (C) obtained by X-ray diffraction are Lc(A) and Lc(C), respectively, Lc( C)/Lc(A) is 1.0 to 5,
(4) The mass content of the carbonaceous material (C) is 14.5% or more based on the total amount of the carbonaceous fiber (A), the carbon particles (B) other than the graphite particles, and the carbonaceous material (C).
(5) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. 22. The carbon electrode material according to the above 21, wherein the mass ratio of the carbonaceous material (C) to the carbon particles (B) is 0.2 to 10.
23. 23. The carbon electrode material as described in 21 or 22 above, which has a BET specific surface area of 0.5 m ² /g or more as determined from the amount of adsorbed nitrogen.
24. 24. The carbon electrode material according to any one of 21 to 23 above, wherein a water flow rate when water drops are dropped is 0.5 mm/sec or more.
25. A redox flow battery comprising the carbon electrode material according to any one of 21 to 24 above.
26. A method for producing the carbon electrode material according to any one of 21 to 24 above,
Attaching carbon particles (B) other than the graphite particles and carbonaceous material (C) before carbonization to the carbonaceous fibers (A);
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order.

According to the 1st-3rd carbon electrode material which concerns on this invention, the cell resistance at the time of initial charge/discharge is reduced, and the carbon electrode material for redox flow batteries excellent in battery energy efficiency is obtained.
The first and second carbon electrode materials according to the present invention are particularly useful as electrode materials for vanadium redox flow batteries.
The third carbon electrode material according to the present invention is for a redox flow battery using not only the vanadium-based electrolytic solution and the Mn/Ti-based electrolytic solution described above, but also other metal-based electrolytic solution and non-metal-based electrolytic solution. It is useful as an electrode material.
Furthermore, the first to third carbon electrode materials according to the present invention are suitably used for flow type and non-flow type redox flow batteries, or redox flow batteries combined with lithium, capacitor, and fuel cell systems.

FIG. 1 is a schematic diagram of a redox flow battery. FIG. 2 is an exploded perspective view of a liquid flow type electrolytic cell having a three-dimensional electrode preferably used in the present invention.

First, the present invention will be described in detail for each component with reference to FIG.

FIG. 2 is an exploded perspective view of a liquid flow type electrolytic cell suitably used in the present invention. In the electrolytic cell of FIG. 2, an ion exchange membrane 3 is disposed between two facing current collector plates 1 and 1, and spacers 2 are provided on both sides of the ion exchange membrane 3 along the inner surface of the current collector plates 1 and 1. Electrolyte passages 4a and 4b are formed. An electrode material 5 is provided on at least one of the liquid passages 4a and 4b. The current collector plate 1 is provided with a liquid inlet 10 and a liquid outlet 11 for the electrolytic solution. As shown in FIG. 2, if the electrode is composed of the electrode material 5 and the current collector plate 1 and the electrolyte solution passes through the electrode material 5 (electrode structure is three-dimensional), the current collector plate 1 transports electrons. It is possible to improve the charge/discharge efficiency by using the entire surface of the pores of the electrode material 5 as an electrochemical reaction field while ensuring the above. As a result, the charging/discharging efficiency of the electrolytic cell is improved.

Hereinafter, the 1st-3rd carbon electrode material (5 in FIG. 2) which concerns on this invention is demonstrated in detail. In this specification, the carbon electrode material may be abbreviated as “electrode material”.

[I. First Carbon Electrode Material According to the Present Invention]
[I-1. Configuration of First Carbon Electrode Material]
The present inventors first reviewed the requirements for carbon particles in order to provide a carbon electrode material having a reduced cell resistance during initial charge and discharge. Generally, carbon blacks such as acetylene black (acetylene soot), oil black (furnace black, oil soot), and gas black (gas soot) are used as particles showing reaction activity in redox flow batteries. Often used are those having high reactivity and high specific surface area and low crystallinity. However, in general, a large amount of binder has to be used in order to bind with the carbon fiber, and sufficient reaction activity cannot be obtained.

In addition to the above, carbon nanotubes (CNTs, carbon nanotubes), carbon nanofibers, carbon aerogels, mesoporous carbon, graphene, graphene oxide, N-doped CNTs, boron-doped CNTs, carbon particles such as fullerenes are also reactive in a redox flow battery. Indicates. However, although they are excellent in reaction activity, they are expensive and rare, and thus are not suitable as a material for an inexpensive electrode material.

On the other hand, graphite particles can be cited as an inexpensive and easily available carbon particle. Graphite particles are very useful because they have good binding properties to carbonaceous materials and can support graphite particles even with a small amount of carbonaceous material. However, since graphite particles have low oxidation resistance, there is a problem that the durability of the electrode is reduced.

Therefore, the present inventors have proposed a carbonaceous material (B) that does not use carbon particles and is a binding carbonaceous material that binds the carbonaceous fiber (A) and the carbonaceous fiber (A). We decided to use a low crystalline carbonaceous material that satisfies the following requirements (1) and (2).
(1) When the crystallite size in the c-axis direction determined by X-ray diffraction is Lc(B), Lc(B) is less than 10 nm. (2) c-axis determined by X-ray diffraction in carbonaceous fiber. When the size of the crystallite in the direction is Lc(A), Lc(B)/Lc(A) is 1.0 or more, where "the carbonaceous fiber (A) is bound to the carbonaceous fiber (A). “(In other words, the carbonaceous material used for the first electrode material acts as a binding agent for the carbonaceous fibers) means that the carbonaceous fibers are strongly bound by the carbonaceous material, It means that the surface of the carbonaceous fiber is covered with the carbonaceous material when viewed as the whole material.
However, it is preferable that the carbonaceous material after binding does not form a film. Here, “not in a coating state” means that the carbonaceous material (B) does not form a webbed state such as whole footpads or footpads between the fibers of the carbonaceous fiber (A). When the coating state is formed, the liquid permeability of the electrolytic solution is deteriorated and the resistance of the battery is increased.

In order to obtain such a binding state, it is preferable to increase the content ratio of the carbonaceous material with respect to the total amount of the carbonaceous fiber and the carbonaceous material, and in the first electrode material, for example, 14.5% or more. Preferably. In this respect, the carbonaceous material in the first electrode material is different from the carbonaceous material described in Patent Document 4 described above. In Patent Document 4, the carbonaceous material to be used exerts an action as a partial adhesive under the idea that only the portion where the carbonaceous fiber and the carbon fine particles are originally in contact with each other can be fixed (adhered). The only recognition is that it should be. Therefore, in the example of Patent Document 4, the carbonaceous material content is 14.4% at most.

When such a binding and low crystalline carbonaceous material is used, it becomes easy to introduce an oxygen functional group, and the carbonaceous material is imparted with high electrolytic solution affinity. Further, it has been found that the carbonaceous material strongly binds between the carbonaceous fibers and the like, so that an efficient conductive path can be formed and an increase in resistance can be suppressed.

Furthermore, the carbon electrode material of the first electrode material satisfies the following requirement (3).
(3) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. Thereby, oxygen atoms can be introduced into the edge surface of carbon or the defect structure portion. As a result, the introduced oxygen atoms are generated on the surface of the electrode material as reactive groups such as carbonyl group, quinone group, lactone group, and free radical type oxides, and these reactive groups greatly contribute to the electrode reaction. However, the increase in resistance is further suppressed.

Since the electrode material of the first electrode material is configured as described above, the reaction activity is enhanced and a low resistance and inexpensive electrode can be obtained.

As described above, the first electrode material 5 is made of the carbonaceous fiber (A) and a binding carbonaceous material that binds the carbonaceous fiber (A), and the requirements (1) to (3) above are satisfied. To be satisfied.

[Carbon fiber (A)]
The carbonaceous fiber used in the first electrode material is a fiber obtained by subjecting an organic fiber precursor to a heating carbonization treatment (details will be described later), and 90% or more by mass of carbon is composed of carbon. Fiber (JIS L 0204-2). As precursors of organic fibers which are raw materials of carbonaceous fibers, acrylic fibers such as polyacrylonitrile; phenol fibers; PBO fibers such as polyparaphenylenebenzobisoxazole (PBO); aromatic polyamide fibers; isotropic pitch fibers, different Pitch fibers such as isotropic pitch fibers and mesophase pitch; cellulose fibers; etc. can be used. Of these, acrylic fiber, phenol fiber, cellulose fiber, isotropic pitch fiber, and anisotropic pitch fiber are preferable as the precursor of the organic fiber, and acrylic fiber is more preferable, from the viewpoint of excellent strength and elastic modulus. The acrylic fiber is not particularly limited as long as it contains acrylonitrile as a main component, but the content of acrylonitrile in the raw material monomer forming the acrylic fiber is preferably 95% by mass or more, and 98% by mass or more. Is more preferable.

The mass average molecular weight of the organic fiber is not particularly limited, but is preferably 10,000 or more and 100,000 or less, more preferably 15,000 or more and 80,000 or less, and further preferably 20,000 or more and 50,000 or less. The mass average molecular weight can be measured by a method such as gel permeation chromatography (GPC) or solution viscosity.

The average fiber diameter of the carbonaceous fibers is preferably 0.5 to 40 μm. If the average fiber diameter is smaller than 0.5 μm, liquid permeability deteriorates. On the other hand, when the average fiber diameter is larger than 40 μm, the reaction surface area of the fiber portion decreases and the cell resistance increases. Considering the balance between liquid permeability and reaction surface area, it is more preferably 3 to 20 μm.

In the first electrode material, it is preferable to use the above-mentioned carbonaceous fiber structure as a base material, which improves strength and facilitates handling and workability. As the structure, specifically, a spun yarn, a filament bundled yarn, a non-woven fabric, a knitted fabric, a woven fabric, a special knitted woven fabric or carbon described in Japanese Patent Laid-Open No. 63-200467, which is a sheet-like product made of carbonaceous fibers. Examples include paper made of fibers. Of these, non-woven fabrics made of carbonaceous fibers, knitted fabrics, woven fabrics, special woven and knitted fabrics, and papers made of carbon fibers are more preferable from the viewpoints of handling, processability, and manufacturability.

When a non-woven fabric, a knitted fabric, a woven fabric or the like is used here, the average fiber length is preferably 30 to 100 mm. When using paper made of carbon fiber, the average fiber length is preferably 5 to 30 mm. Within the above range, a uniform fiber structure can be obtained.

As described above, the carbonaceous fiber is obtained by subjecting an organic fiber precursor to a heating carbonization treatment. The “heating carbonization treatment” includes at least a flameproofing step and a carbonization (firing) step. Is preferred. However, among these, the carbonization step does not necessarily have to be performed after the flameproofing step as described above, and after attaching the graphite particles and the carbonaceous material to the flameproofed fiber as described in Examples described later. A carbonization step may be performed, and in this case, the carbonization step after the flameproofing step can be omitted.

Of these, the flameproofing step means a step of heating the precursor of the organic fiber at a temperature of preferably 180°C or higher and 350°C or lower in an air atmosphere to obtain the flameproofed organic fiber. The heat treatment temperature is more preferably 190° C. or higher, further preferably 200° C. or higher. Further, it is preferably 330° C. or lower, and more preferably 300° C. or lower. By heating in the above temperature range, the content ratio of nitrogen and hydrogen in the organic fiber can be reduced and the carbonization ratio can be improved while the organic fiber is not thermally decomposed and the form of the carbonaceous fiber is maintained. During the flameproofing step, the organic fiber may be thermally shrunk to collapse the molecular orientation, and the conductivity of the carbonaceous fiber may decrease, so it is preferable to subject the organic fiber to flameproofing under tension or stretching. More preferably, the flameproof treatment is performed under tension.

In the carbonization step, the flame-resistant organic fiber obtained as described above is heated at a temperature of preferably 1000° C. or higher and 2000° C. or lower in an inert atmosphere (preferably under a nitrogen atmosphere) to obtain a carbonaceous fiber. Means a process. The heating temperature is more preferably 1100° C. or higher, still more preferably 1200° C. or higher. Further, it is more preferably 1900° C. or lower. By carrying out the carbonization step in the above temperature range, carbonization of the organic fiber proceeds, and a carbonaceous fiber having a pseudo-graphite crystal structure can be obtained.

Since the organic fibers have different crystallinities, the heating temperature in the carbonization step can be selected according to the type of the organic fibers used as the raw material. For example, when an acrylic resin (preferably polyacrylonitrile) is used as the organic fiber, the heating temperature is preferably 800° C. or higher and 2000° C. or lower, and more preferably 1000° C. or higher and 1800° C. or lower.

The flameproofing step and the carbonization step described above are preferably performed continuously, and the rate of temperature rise when raising the temperature from the flameproofing temperature to the carbonization temperature is preferably 20° C./min or less, and more preferably Is 15°C/min or less. By setting the heating rate within the above range, it is possible to obtain a carbonaceous fiber which retains the shape of the organic fiber and is excellent in mechanical properties. The lower limit of the temperature rising rate is preferably 5° C./min or more in consideration of mechanical properties and the like.

As will be described in detail later in the section of carbonaceous material (B), the first electrode material is, as defined in (2) above, in the carbonaceous fiber (A) and the carbonaceous material (B), When the crystallite sizes in the c-axis direction obtained by X-ray diffraction are Lc(A) and Lc(B), respectively, Lc(B)/Lc(A) satisfies 1.0 or more. Therefore, in the first electrode material, Lc(A) in the carbonaceous fiber (A) is not particularly limited as long as the above (2) is satisfied, but it is preferably 1 to 10 nm. As a result, it exhibits appropriate electronic conductivity, has oxidation resistance to a sulfuric acid solvent, etc., and effectively exerts the effect of easily providing an oxygen functional group. More preferably, Lc(A) is 1 to 6 nm. The method for measuring Lc(A) and Lc(B) will be described in detail in the section of Examples below.

[Carbonaceous material (B)]
In the first electrode material, the carbonaceous material is originally added as a binder (binder) for strongly binding the carbonaceous fibers that cannot be bound. In the first electrode material, when the crystallite size in the c-axis direction in the carbonaceous material (B) determined by X-ray diffraction is Lc(B) as defined in (1) above, Lc( B) is less than 10 nm, and as defined in (2) above, the size of the crystallite in the c-axis direction in the carbonaceous fiber (A) determined by X-ray diffraction is Lc(B). At this time, Lc(B)/Lc(A) needs to satisfy 1.0 or more.
By using such a low crystalline binder carbonaceous material, it becomes easy to introduce an oxygen functional group, and the carbonaceous material is provided with a high affinity for an electrolytic solution. Further, it has been found that the carbonaceous material strongly binds the carbonaceous fibers, so that an efficient conductive path can be formed and the effect of lowering resistance can be effectively exhibited.

From the viewpoint of reducing the resistance, Lc(B) is preferably 8 nm or less, and more preferably 5 nm or less. The lower limit of Lc(B) is not particularly limited from the above viewpoint, but considering the oxidation resistance and the like required in the vanadium redox flow battery, it is preferably about 1 nm or more.

If the ratio of Lc(B)/Lc(A) is less than 1.0, the above effect cannot be effectively exhibited. The above ratio is preferably 1.5 or more, more preferably 3.0 or more. On the other hand, when the above ratio exceeds 10, it becomes difficult for oxygen functional groups to be imparted to the carbonaceous material portion, so 10 or less is preferable. The ratio is preferably 5 or less, more preferably 4 or less.

In the first electrode material, the range of Lc(B) is not particularly limited as long as the ratio of Lc(B)/Lc(A) satisfies the above range, but from the viewpoint of further lowering the resistance, Lc(B) Is preferably 10 nm or less, more preferably 7.5 nm or less. The lower limit of Lc(B) is not particularly limited from the above viewpoint, but in consideration of electron conductivity and the like, it is preferably about 3 nm or more.

The carbonaceous material (B) used for the first electrode material is contained in a mass ratio of 14.5% or more with respect to the total amount of the above-mentioned carbonaceous fiber (A) and carbonaceous material (B). It is preferably 20% or more, and more preferably 20% or more. By increasing the content ratio of the carbonaceous material in this way, the carbonaceous fibers can be sufficiently bound, and the binding action due to the addition of the carbonaceous material is effectively exhibited. The upper limit is preferably about 60% or less in consideration of the fluid pressure loss. It is more preferably 50% or less. The content of the carbonaceous fiber (A) used for calculating the content is the content of the structure when a structure such as a nonwoven fabric is used as the base material.

The carbonaceous material (B) used for the first electrode material may be of any type as long as it can bind the carbonaceous fiber (A). Specifically, at the time of carbonization during the production of the first electrode material. There is no particular limitation as long as it exhibits binding properties. Examples thereof include pitches such as coal tar pitch and coal pitch; phenol resin, benzoxazine resin, epoxide resin, furan resin, vinyl ester resin, melanin-formaldehyde resin, urea-formaldehyde resin, resorcinol-formaldehyde. Resin, cyanate ester resin, bismaleimide resin, polyurethane resin, resin such as polyacrylonitrile; furfuryl alcohol; rubber such as acrylonitrile-butadiene rubber. You may use a commercial item for these.

Of these, particularly easily crystallizable pitches such as coal tar pitch and coal pitch are preferable because the target carbonaceous material (B) can be obtained at a low firing temperature. Further, a phenol resin is also preferably used because the increase or decrease in crystallinity due to the firing temperature is small and the crystallinity is easily controlled. Further, a polyacrylonitrile resin is also preferably used because the intended carbonaceous material (B) can be obtained by raising the firing temperature. Particularly preferred are pitches.
According to the preferable mode of the first electrode material, since the phenol resin is not used, the harmful effects (formaldehyde generation and formaldehyde odor at room temperature) caused by the phenol resin do not occur, and there is an advantage that no odor is generated at room temperature. On the other hand, in Patent Document 4 described above, since the phenol resin is used as the adhesive, in addition to the above-mentioned adverse effects, equipment for controlling the formaldehyde concentration in the work place below the control concentration is additionally required There is a disadvantage in terms of work.

Here, the pitches that are preferably used will be described in detail. The content rate of the mesophase phase (liquid crystal phase) of the above-mentioned coal tar pitch or coal-based pitch can be controlled by the temperature and time of the infusibilizing treatment. If the content of the mesophase phase is low, it can be melted at a relatively low temperature or in a liquid state at room temperature. On the other hand, when the content of the mesophase phase is high, the mesophase phase is melted at a high temperature and a high carbonization yield is obtained. When the pitches are applied to the carbonaceous material (B), the mesophase phase content is preferably low (that is, the carbonization yield is low), for example, 10% or less is preferable. The melting point of the pitches is preferably 200°C or lower, more preferably 100°C or lower. Thereby, the above effect is effectively exhibited.

[I-2. Characteristics of first carbon electrode material]
In the first electrode material, the number of bonded oxygen atoms on the surface of the carbon electrode material satisfies 1.0% or more of the total number of carbon atoms on the surface of the carbon electrode material. Hereinafter, the ratio of the number of bonded oxygen atoms to the total number of carbon atoms may be abbreviated as O/C. O/C can be measured by surface analysis such as X-ray photoelectron spectroscopy (XPS) and fluorescent X-ray analysis.

By using an electrode material having O/C of 1.0% or more, the electrode reaction rate can be remarkably increased, so that low resistance can be obtained. Further, the hydrophilicity can be enhanced by controlling the O/C, and the water flow rate (preferably 0.5 mm/sec or more) of the electrode material described later can be secured. On the other hand, when an electrode material having a low oxygen concentration of O/C of less than 1.0% is used, the electrode reaction rate at the time of discharge becomes low and the electrode reaction activity cannot be increased. As a result, the resistance increases. The details of the reason why the electrode reaction activity (in other words, voltage efficiency) can be improved by using the electrode material in which a large number of oxygen atoms are bonded to the surface of the electrode material are not clear, but the oxygen atoms existing in large numbers on the surface are carbonaceous. It is considered that the material (B) effectively acts on the affinity between the material (B) and the electrolytic solution, the transfer of electrons, the desorption of complex ions from the carbonaceous material, and the complex exchange reaction.

The first electrode material has excellent hydrophilicity. The hydrophilicity can be confirmed by the water flow rate when water drops are dripped after the electrode material is subjected to the dry oxidation treatment. The water flow rate of the first electrode material is preferably 0.5 mm/sec or more. From this, it can be determined that it has a sufficient affinity for the electrolytic solution. The higher the water flow rate of the electrode material is, the more preferable it is, more preferably 1 mm/sec or more, further preferably 5 mm/sec or more, and further more preferably 10 mm/sec or more.

The weight of the first electrode material is 50 to 50 when the thickness of the spacer 2 sandwiched between the current collector 1 and the ion exchange membrane 3 (hereinafter referred to as "spacer thickness") is 0.3 to 3 mm. preferably ^{500g / m 2, 100~400g / m} 2 is more preferable. By controlling the basis weight within the above range, it is possible to prevent the ion exchange membrane 3 from being damaged while ensuring liquid permeability. In particular, in recent years, from the viewpoint of lowering the resistance, the thickness of the ion exchange membrane 3 tends to be thin, and a treatment and a use method for reducing damage to the ion exchange membrane 3 are extremely important. From the above viewpoint, it is more preferable to use, as the first electrode material, a nonwoven fabric or paper whose one surface is flattened as a base material. As the flattening method, any known method can be applied, and examples thereof include a method of coating the slurry on one side of the carbonaceous fiber and drying; a method of impregnating and drying on a smooth film such as PET.

The thickness of the first electrode material is preferably at least greater than the spacer thickness. For example, when a carbon fiber having a low density such as a non-woven fabric is used and graphite particles or a binding carbonaceous material used for the first electrode material is carried on the carbon fiber, the spacer thickness of 1.5 to It is preferably 6.0 times. However, if the thickness is too thick, the ion-exchange membrane 3 may break through due to the compressive stress of the sheet-like material, so it is recommended to use the first electrode material having a compressive stress of 9.8 N/cm ² or less. preferable. In order to adjust the compressive stress or the like according to the basis weight/thickness of the first electrode material, it is also possible to use the first electrode material by laminating two layers or three layers. Alternatively, a combination with another form of electrode material is also possible.

[I-3. First carbon electrode material manufacturing method]
Next, a method of manufacturing the first electrode material will be described. The first electrode material can be produced through a carbonization step, a graphitization step, and an oxidation treatment step after a carbonaceous fiber (base material) is impregnated with a carbonaceous material precursor (before carbonization). .. A known method can be arbitrarily applied to each step.

Each step will be described below.

(Step of attaching carbonaceous material precursor to carbonaceous fiber)
First, a carbonaceous material precursor is attached to the carbonaceous fiber. A publicly known method can be arbitrarily adopted for the above step. For example, a method of heating the above-mentioned carbonaceous material precursor to melt it, immersing the carbonaceous fiber in the obtained melt, and then cooling it to room temperature can be mentioned. Alternatively, the above carbonaceous material precursor is dispersed in a solvent such as water or alcohol, or is partially dissolved or partially dispersed in a solvent such as toluene, and the carbonaceous fiber is immersed in this dispersion and dried by heating. Can be used. Here, excess liquid (pickup amount) of the above-mentioned melt, dispersion or solution in which carbonaceous fibers are dipped is passed through a nip roller provided with a predetermined clearance to squeeze the product after attachment, or Can be removed by a method such as scraping the surface of the product after attachment with a doctor blade or the like.

Then, it is dried in an air atmosphere, for example, at 80 to 150°C.

(Carbonization process)
The carbonization step is performed for firing the product after the impregnation obtained in the above step. As a result, the carbonaceous fibers are bound together. In the carbonization step, it is preferable to sufficiently remove the decomposition gas at the time of carbonization, and for example, it is preferable to heat at a temperature of 800° C. or higher and 2000° C. or lower under an inert atmosphere (preferably under a nitrogen atmosphere). The heating temperature is more preferably 1000° C. or higher, further preferably 1200° C. or higher, further preferably 1300° C. or higher, further preferably 1500° C. or lower, further preferably 1400° C. or lower.

As described above, the treatment corresponding to the carbonization step may be performed after the fiber is made flame resistant, but the carbonization treatment performed after the fiber is made flame resistant may be omitted. That is, the method of manufacturing the first electrode material is roughly classified into the following method 1 and method 2.
・Method 1: Fiber flame resistance→fiber carbonization→carbonaceous material impregnation→carbonization→graphitization→oxidation Method 2: fiber flame resistance→carbonaceous material impregnation→carbonization→graphitization→oxidation According to the method 1, although carbonization is performed twice, the processing cost is increased, but the sheet used as the electrode material is not easily affected by the difference in the volume contraction ratio, and thus the obtained sheet is not easily deformed (warped). There is an advantage that. On the other hand, according to the method 2, although the carbonization step may be performed once, the processing cost can be reduced, but the sheet obtained is easily deformed due to the difference in the volume contraction ratio of each material at the time of carbonization. Which of the above methods 1 and 2 should be adopted may be appropriately determined in consideration of these.

(Graphitization process)
The graphitization step is a step performed to sufficiently enhance the crystallinity of the carbonaceous material, improve the electron conductivity, and improve the oxidation resistance to a sulfuric acid solution in the electrolytic solution. After the carbonization step, it is preferable to further heat at a temperature of 1300° C. or higher in an inert atmosphere (preferably under a nitrogen atmosphere) and higher than the heating temperature of the carbonization step, 1500 C. or higher is more preferable. Note that the upper limit is preferably 2000° C. or lower in consideration of imparting high affinity for the electrolytic solution to the carbonaceous material.
On the other hand, Patent Document 4 described above is different from the second electrode material manufacturing method in that the graphitization step is not performed.

(Oxidation process)
After the above graphitization step, by further performing an oxidation treatment step, oxygen functional groups such as hydroxyl groups, carbonyl groups, quinone groups, lactone groups, and free radical oxides are introduced on the surface of the electrode material. Become. As a result, the above-mentioned O/C ratio≧1% can be achieved. Since these oxygen functional groups greatly contribute to the electrode reaction, sufficiently low resistance can be obtained. Also, the water flow rate can be increased.

As the oxidation treatment process, various treatment processes such as wet chemical oxidation, electrolytic oxidation, and dry oxidation can be applied, but the dry oxidation treatment process is preferable from the viewpoint of processability and manufacturing cost. The dry oxidation treatment step means a step of heating (oxidation treatment) at 500° C. or higher and 900° C. or lower in an air atmosphere. In order to effectively exert the effect of introducing the oxygen functional group, the heating temperature is more preferably 600° C. or higher, further preferably 650° C. or higher. Moreover, 800° C. or lower is more preferable, and 750° C. or lower is further preferable.

Further, in the dry oxidation treatment step, from the viewpoint of maintaining the mechanical strength of the electrode material, it is preferable to adjust the mass yield of the electrode material before and after the oxidation treatment to 90% or more and 96% or less. This can be adjusted by, for example, appropriately adjusting the processing time or temperature of dry air oxidation.

[II. Second Carbon Electrode Material According to the Present Invention]
[II-1. Configuration of Second Carbon Electrode Material]
The present inventors first reviewed the requirements for carbon particles in order to provide a carbon electrode material having a reduced cell resistance during initial charge and discharge. Generally, carbon blacks such as acetylene black (acetylene soot), oil black (furnace black, oil soot), and gas black (gas soot) are used as particles showing reaction activity in a redox flow battery. Often used are those having high reactivity and high specific surface area and low crystallinity. However, in general, a large amount of binder has to be used in order to bind with the carbon fiber, and sufficient reaction activity cannot be obtained.

In addition to the above, carbon nanotubes (CNTs, carbon nanotubes), carbon nanofibers, carbon aerogels, mesoporous carbon, graphene, graphene oxide, N-doped CNTs, boron-doped CNTs, carbon particles such as fullerenes are also reactive in a redox flow battery. Indicates. However, although they are excellent in reaction activity, they are expensive and rare, and thus are not suitable as a material for an inexpensive electrode material.

Therefore, the present inventors decided to use inexpensive and easily available graphite particles (B) as the carbon particles. Graphite particles are very useful because they have good binding properties to carbonaceous materials and can support graphite particles even with a small amount of carbonaceous material.

Specifically, it has been decided to adopt highly crystalline graphite particles that satisfy the following requirement (1).
(1) When the crystallite size in the c-axis direction determined by X-ray diffraction is Lc(B), Lc(B) is less than 35 nm. If graphite particles satisfying the above requirements are used, carbon as a reaction field is used. The edge surface can be exposed abundantly, and low resistance can be achieved.

Furthermore, the carbonaceous material (C) is a binding carbonaceous material that binds both the carbonaceous fiber (A) and the graphite particles (B), and satisfies the following requirements (2) and (3). We decided to use a carbonaceous material that has a low binding rate.
(2) When the size of the crystallite in the c-axis direction obtained by X-ray diffraction is Lc(C), Lc(C) is less than 10 nm. (3) Obtained by X-ray diffraction in the carbonaceous fiber (A) When the crystallite size in the c-axis direction is Lc(A), Lc(C)/Lc(A) is 1.0 or more, where "both carbonaceous fiber (A) and graphite particles (B)""(In other words, the carbonaceous material used for the second electrode material acts as a binder for the carbonaceous fiber and the graphite particles)" means that the carbonaceous material causes the carbonaceous fiber and the graphite particles to adhere. Surface (including carbonaceous fibers and graphite particles) is strongly bound, and the carbonaceous material is covered with the carbonaceous material and the surface of the graphite particles is exposed when the electrode material as a whole is seen. It means that it is configured as follows.
However, it is preferable that the carbonaceous material after binding does not form a film. Here, "not in a coating state" means that the carbonaceous material (C) does not form a webbed state such as whole footpads or footpads between the carbonaceous fibers (A). This is because, when a film state is formed, the liquid permeability of the electrolytic solution deteriorates and the reaction surface area of the graphite particles cannot be effectively used.

In order to obtain such a binding state, it is preferable to increase the content ratio of the carbonaceous material with respect to the total amount of the carbonaceous fiber, the graphite particles, and the carbonaceous material. In the second electrode material, for example, 20% or more. And In this respect, the carbonaceous material in the second electrode material is different from the carbonaceous material described in Patent Document 4 described above. In Patent Document 4, the carbonaceous material to be used exerts an action as a partial adhesive under the idea that only the portion where the carbonaceous fiber and the carbon fine particles are originally in contact with each other can be fixed (adhered). This is because there is only the recognition that it should be done. Therefore, in the example of Patent Document 4, the carbonaceous material content is 14.4% at most.

When such a binding and low crystalline carbonaceous material is used, oxygen functional groups are easily introduced, and the carbonaceous material binding the graphite particles is imparted with a high affinity for an electrolytic solution. In addition, since the carbonaceous material strongly bonds between the carbonaceous fibers through the graphite particles, an efficient conductive path can be formed, and the above-mentioned effect of reducing the resistance by adding the graphite particles can be more effectively exhibited. There was found.

Furthermore, the second carbon electrode material satisfies the following requirement (4).
(4) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. Thereby, oxygen atoms can be introduced into the edge surface of carbon or the defect structure portion. As a result, the introduced oxygen atoms are generated on the surface of the electrode material as reactive groups such as carbonyl group, quinone group, lactone group, and free radical type oxides, and these reactive groups greatly contribute to the electrode reaction. However, a sufficiently low resistance can be obtained.

Since the second electrode material is configured as described above, the reaction activity is enhanced and a low resistance and inexpensive electrode can be obtained.

As described above, the second electrode material 5 is an electrode material in which the carbonaceous fiber (A) is used as a base material and the graphite particles (B) are carried by the low crystalline carbonaceous material (C), and the above (1 )-(4) are satisfied. Details of each requirement are as follows.

[Carbon fiber (A)]
The carbonaceous fiber used for the second electrode material is a fiber obtained by subjecting a precursor of an organic fiber to a heating carbonization treatment (details will be described later), and 90% by mass or more is composed of carbon. It means a fiber (JIS L 0204-2). As precursors of organic fibers which are raw materials of carbonaceous fibers, acrylic fibers such as polyacrylonitrile; phenol fibers; PBO fibers such as polyparaphenylenebenzobisoxazole (PBO); aromatic polyamide fibers; isotropic pitch fibers, different Pitch fibers such as isotropic pitch fibers and mesophase pitch; cellulose fibers; etc. can be used. Of these, acrylic fiber, phenol fiber, cellulose fiber, isotropic pitch fiber, and anisotropic pitch fiber are preferable as the precursor of the organic fiber, and acrylic fiber is more preferable, from the viewpoint of excellent strength and elastic modulus. The acrylic fiber is not particularly limited as long as it contains acrylonitrile as a main component, but the content of acrylonitrile in the raw material monomer forming the acrylic fiber is preferably 95% by mass or more, and 98% by mass or more. Is more preferable.

The mass average molecular weight of the organic fiber is not particularly limited, but is preferably 10,000 or more and 100,000 or less, more preferably 15,000 or more and 80,000 or less, and further preferably 20,000 or more and 50,000 or less. The mass average molecular weight can be measured by a method such as gel permeation chromatography (GPC) or solution viscosity.

The average fiber diameter of the carbonaceous fibers is preferably 0.5 to 40 μm. If the average fiber diameter is smaller than 0.5 μm, liquid permeability deteriorates. On the other hand, when the average fiber diameter is larger than 40 μm, the reaction surface area of the fiber portion is reduced and the cell resistance is increased. Considering the balance between liquid permeability and reaction surface area, it is more preferably 3 to 20 μm.

In the second electrode material, the carbonaceous fiber structure is preferably used as a base material, which improves strength and facilitates handling and workability. As the structure, specifically, a spun yarn, a filament bundled yarn, a non-woven fabric, a knitted fabric, a woven fabric, a special knitted woven fabric or carbon described in Japanese Patent Laid-Open No. 63-200467, which is a sheet-like product made of carbonaceous fibers. Examples include paper made of fibers. Of these, non-woven fabrics made of carbonaceous fibers, knitted fabrics, woven fabrics, special woven and knitted fabrics, and papers made of carbon fibers are more preferable from the viewpoints of handling, processability, and manufacturability.

When a non-woven fabric, a knitted fabric, a woven fabric or the like is used here, the average fiber length is preferably 30 to 100 mm. When using paper made of carbon fiber, the average fiber length is preferably 5 to 30 mm. Within the above range, a uniform fiber structure can be obtained.

As described above, the carbonaceous fiber is obtained by subjecting an organic fiber precursor to a heating carbonization treatment. The “heating carbonization treatment” includes at least a flameproofing step and a carbonization (firing) step. Is preferred. However, among these, the carbonization step does not necessarily have to be performed after the flameproofing step as described above, and after attaching the graphite particles and the carbonaceous material to the flameproofed fiber as described in Examples described later. A carbonization step may be performed, and in this case, the carbonization step after the flameproofing step can be omitted.

Of these, the flameproofing step means a step of heating the precursor of the organic fiber at a temperature of preferably 180°C or higher and 350°C or lower in an air atmosphere to obtain the flameproofed organic fiber. The heat treatment temperature is more preferably 190° C. or higher, further preferably 200° C. or higher. Further, it is preferably 330° C. or lower, and more preferably 300° C. or lower. By heating in the above temperature range, the content ratio of nitrogen and hydrogen in the organic fiber can be reduced and the carbonization ratio can be improved while the organic fiber is not thermally decomposed and the form of the carbonaceous fiber is maintained. During the flameproofing step, the organic fiber may be thermally shrunk to collapse the molecular orientation, and the conductivity of the carbonaceous fiber may decrease, so it is preferable to subject the organic fiber to flameproofing under tension or stretching. More preferably, the flameproof treatment is performed under tension.

In the carbonization step, the flame-resistant organic fiber obtained as described above is heated at a temperature of preferably 1000° C. or higher and 2000° C. or lower in an inert atmosphere (preferably under a nitrogen atmosphere) to obtain a carbonaceous fiber. Means a process. The heating temperature is more preferably 1100° C. or higher, still more preferably 1200° C. or higher. Further, it is more preferably 1900° C. or lower. By carrying out the carbonization step in the above temperature range, carbonization of the organic fiber proceeds, and a carbonaceous fiber having a pseudo-graphite crystal structure can be obtained.

Since the organic fibers have different crystallinities, the heating temperature in the carbonization step can be selected according to the type of the organic fibers used as the raw material. For example, when an acrylic resin (preferably polyacrylonitrile) is used as the organic fiber, the heating temperature is preferably 800° C. or higher and 2000° C. or lower, and more preferably 1000° C. or higher and 1800° C. or lower.

The flameproofing step and the carbonization step described above are preferably performed continuously, and the rate of temperature rise when raising the temperature from the flameproofing temperature to the carbonization temperature is preferably 20° C./min or less, and more preferably Is 15°C/min or less. By setting the heating rate within the above range, it is possible to obtain a carbonaceous fiber which retains the shape of the organic fiber and is excellent in mechanical properties. The lower limit of the temperature rising rate is preferably 5° C./min or more in consideration of mechanical properties and the like.

When the size of the crystallite in the c-axis direction in the carbonaceous fiber (A) determined by X-ray diffraction is Lc(A), Lc(A) is preferably 1 to 6 nm. As a result, it exhibits appropriate electronic conductivity, has oxidation resistance to a sulfuric acid solvent, etc., and effectively exerts the effect of easily providing an oxygen functional group. The method for measuring Lc(A) will be described in detail in the section of Examples below.

[Graphite particles (B)]
In the second electrode material, the graphite particles are useful for abundantly exposing the carbon edge surface, which is the reaction field, to realize low resistance. According to the examination results of the present inventors, when the crystallite size in the c-axis direction obtained by X-ray diffraction is Lc(B) for the graphite particles, the value of Lc(B) is It is found that the carbon edge surface is sufficiently exposed and the reactivity is improved when Lc(B) is less than 35 nm, which is correlated with the degree of exposure, and thus low resistance can be realized. Lc(B) is preferably 33 nm or less, more preferably 30 nm or less. The lower limit of the above value is not particularly limited from the above viewpoint, but in consideration of ensuring conductivity and oxidation resistance, it is preferably about 15 nm or more. The method for measuring Lc(B) will be described in detail in the section of Examples below.

Graphite particles are generally classified into natural graphite and artificial graphite. Examples of natural graphite include scaly graphite, scaly graphite, earthy graphite, spheroidal graphite, exfoliated graphite, and the like, and artificial graphite includes, for example, expanded graphite and oxidized graphite. In the second electrode material, either natural graphite or artificial graphite can be used. Among them, oxidized graphite, scaly graphite, scaly graphite, earthy graphite, exfoliated graphite and expanded graphite are used as reaction fields. It is preferable to have a carbon edge surface of. Among them, flake graphite, exfoliated graphite, and expanded graphite are more preferable because not only the carbon edge surface is extremely exposed and low resistance is obtained, but also low cost and abundant resources are available. These scaly graphite, exfoliated graphite and expanded graphite may be added alone or in combination of two or more. Here, the flake graphite means a flaky appearance. Flake graphite is different from scaly graphite (the shape is lumpy and is sometimes called lumpy graphite).

The graphite particles (B) used in the second electrode material are 14.5% by mass ratio with respect to the total amount of the carbonaceous fibers (A), the graphite particles (B), and the carbonaceous material (C) described later. It is preferably contained in the above amount, more preferably 20% or more, still more preferably 25% or more. As a result, the graphite particles become bound with the carbonaceous material, and the characteristics of the graphite particles (B) can be sufficiently exhibited. However, when the amount of the graphite particles (B) is excessive, the binding property with the carbonaceous material becomes insufficient, and the graphite particles involved in the reaction decrease. Further, since the fluid pressure loss also increases, the desired low resistance cannot be obtained. Therefore, the upper limit is preferably about 60% or less, more preferably about 50% or less. The content of the carbonaceous fiber (A) used for calculating the content is the content of the structure when a structure such as a nonwoven fabric is used as the base material.

In the second electrode material, the mass ratio of the carbonaceous material (C) described below to the graphite particles (B) is preferably 0.2 or more and 3.0 or less, and 0.3 or more and 2.5 or less. More preferably. When the above ratio is less than 0.2, the graphite particles are more likely to fall off, the graphite particles are not sufficiently bound to the carbonaceous material, and the graphite particles involved in the reaction are reduced. On the other hand, when the above ratio exceeds 3.0, the carbon edge surface of the graphite particles, which is the reaction field, is covered with the carbonaceous material, and the desired low resistance cannot be obtained.

The particle size of the graphite particles (B) used for the second electrode material is not particularly limited, but considering the specific surface area of the graphite and the like, it is preferably within the range of about 0.1 to 15 μm. Here, the "particle diameter" means an average particle diameter (D50) at a median 50% diameter in a particle diameter distribution obtained by a dynamic light scattering method or the like. As the graphite particles, commercially available products may be used, and in that case, the particle size described in the catalog can be adopted.

Graphite particles used in the second electrode member (B), BET specific surface area determined from nitrogen adsorption amount is 20 m ² / g greater are preferred, more preferably at least 21m ² / g, more preferably more than 30 m ² / g .. When the BET specific surface area is 20 m ² /g or less, the exposure of the edge surface of the graphite particles (B) is reduced and the contact area with the electrolytic solution is reduced, so that the desired low resistance cannot be obtained. Although the upper limit is not particularly limited from the above viewpoint, it is preferably about 300 m ² /g or less in consideration of the oxidation resistance and the binding property with the binder. Here, the “BET specific surface area obtained from the amount of adsorbed nitrogen” means a specific surface area calculated by adsorbing gas molecules on solid particles and adsorbing the gas molecules.

[Carbonaceous material (C)]
The carbonaceous material used for the second electrode material is originally added as a binder (binder) for strongly binding the carbonaceous fibers that cannot be bound and the graphite particles. In the second electrode material, when the crystallite size in the c-axis direction in the carbonaceous material (C) determined by X-ray diffraction is Lc(C) as defined in (2) above, Lc( C) satisfies less than 10 nm, and as defined in (3) above, the crystallite size in the c-axis direction in the carbonaceous fiber (A) determined by X-ray diffraction is defined as Lc(A). At this time, Lc(C)/Lc(A) needs to satisfy 1.0 or more.
By using such a low-crystallinity binding carbonaceous material, it becomes easy to introduce an oxygen functional group, and a high affinity for an electrolytic solution is imparted to the carbonaceous material binding the graphite particles. As a result, a desired low resistance can be obtained. In addition, since the carbonaceous material strongly bonds between the carbonaceous fibers through the graphite particles, an efficient conductive path can be formed, and the above-mentioned effect of reducing the resistance by adding the graphite particles can be more effectively exhibited. There was found.

From the viewpoint of low resistance, Lc(C) is preferably 8 nm or less, and more preferably 5 nm or less. When Lc(C) is less than 2 nm, the conductivity of the carbonaceous material (C) cannot be sufficiently exhibited, and it becomes difficult to obtain a desired low resistance. Therefore, Lc(C) is preferably 2 nm or more and 3 nm. The above is more preferable.

Further, as described above, the ratio of Lc(C)/Lc(A) is 1.0 or more. That is, in the second electrode material, since Lc(C) is larger than Lc(A), the carbonaceous material (C) has high conductivity and becomes a lower resistance electrode material. The ratio is preferably 2 or more, more preferably 3 or more. However, the upper limit is preferably 5 or less in consideration of the balance between ensuring the conductivity and the affinity for the electrolytic solution.

The carbonaceous material (C) used for the second electrode material is 14.5% or more by mass ratio with respect to the total amount of the above-mentioned carbonaceous fiber (A), graphite particles (B), and carbonaceous material (C). It is preferably contained, more preferably 20% or more, still more preferably 30% or more. By increasing the content ratio of the carbonaceous material in this manner, both the carbonaceous fiber and the graphite particles can be sufficiently bound, and the binding action due to the addition of the carbonaceous material is effectively exhibited. The upper limit is preferably about 60% or less in consideration of the fluid pressure loss. It is more preferably 50% or less.

The carbonaceous material (C) used for the second electrode material may be of any type as long as it can bind the carbonaceous fibers (A) and the graphite particles (B), and specifically, the second electrode. The material is not particularly limited as long as it exhibits binding properties during carbonization during material production. Examples thereof include pitches such as coal tar pitch and coal pitch; phenol resin, benzoxazine resin, epoxide resin, furan resin, vinyl ester resin, melanin-formaldehyde resin, urea-formaldehyde resin, resorcinol-formaldehyde. Resin, cyanate ester resin, bismaleimide resin, polyurethane resin, resin such as polyacrylonitrile; furfuryl alcohol; rubber such as acrylonitrile-butadiene rubber. You may use a commercial item for these.

Of these, particularly easily crystallizable pitches such as coal tar pitch and coal pitch are preferable because the target carbonaceous material (C) can be obtained at a low firing temperature. Further, a phenol resin is also preferably used because the increase or decrease in crystallinity due to the firing temperature is small and the crystallinity is easily controlled. Also, a polyacrylonitrile resin is preferably used because the desired carbonaceous material (C) can be obtained at a low firing temperature. Particularly preferred are pitches.
According to the preferable mode of the second electrode material, since the phenol resin is not used, the harmful effects (formaldehyde generation and formaldehyde odor at room temperature) caused by the phenol resin do not occur, and there is an advantage that no odor is generated at room temperature. On the other hand, in Patent Document 4 described above, since the phenol resin is used as the adhesive, in addition to the above-mentioned adverse effects, equipment for controlling the formaldehyde concentration at the work place below the control concentration is additionally required There is a disadvantage in terms of work.

Here, the pitches that are particularly preferably used will be described in detail. The content rate of the mesophase phase (liquid crystal phase) of the above-mentioned coal tar pitch or coal-based pitch can be controlled by the temperature and time of the infusibilizing treatment. When the content of the mesophase phase is small, it can be obtained by melting at a relatively low temperature or in a liquid state at room temperature. On the other hand, when the content of the mesophase phase is high, the mesophase phase is melted at a high temperature and a high carbonization yield is obtained. When the pitches are applied to the carbonaceous material (C), the mesophase phase content is preferably high (that is, the carbonization rate is high), for example, 30% or more is preferable, and 50% or more is more preferable. Thereby, the fluidity at the time of melting can be suppressed, and the carbonaceous fibers can be bound via the graphite particles without excessively covering the surface of the graphite particles. The upper limit is preferably, for example, 90% or less in consideration of the expression of binding property.

From the same viewpoint as above, the melting point of the pitches is preferably 100° C. or higher, and more preferably 200° C. or higher. Thereby, in addition to the above effects, the odor during the attachment process can be suppressed, which is also preferable in terms of processability. The upper limit is preferably, for example, 350° C. or lower in consideration of the expression of binding property.

[II-2. Characteristics of second carbon electrode material]
In the second electrode material, the number of bonded oxygen atoms on the surface of the carbon electrode material satisfies 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. Hereinafter, the ratio of the number of bonded oxygen atoms to the total number of carbon atoms may be abbreviated as O/C. O/C can be measured by surface analysis such as X-ray photoelectron spectroscopy (XPS) and fluorescent X-ray analysis.

By using an electrode material having O/C of 1% or more, the electrode reaction rate can be remarkably increased, and a low resistance can be obtained. Further, the hydrophilicity can be enhanced by controlling the O/C, and the water flow rate (preferably 0.5 mm/sec or more) of the electrode material described later can be secured. On the other hand, when an electrode material having a low oxygen concentration of O/C of less than 1% is used, the electrode reaction rate at the time of discharge becomes low and the electrode reaction activity cannot be increased. As a result, the resistance increases. The details of the reason why the electrode reaction activity (in other words, voltage efficiency) can be improved by using the electrode material in which a large number of oxygen atoms are bonded to the surface of the electrode material are not clear, but the oxygen atoms existing in large numbers on the surface are carbonaceous. It is considered that this is because it is effectively acting on the affinity between the material (C) and the electrolytic solution, transfer of electrons, desorption of complex ions from the carbonaceous material, complex exchange reaction, and the like.

The second electrode material has excellent hydrophilicity. The hydrophilicity can be confirmed by the water flow rate when water drops are dripped after the electrode material is subjected to the dry oxidation treatment. The water flow rate of the second electrode material is preferably 0.5 mm/sec or more. From this, it can be determined that it has a sufficient affinity for the electrolytic solution. The higher the water flow rate of the electrode material is, the more preferable it is, more preferably 1 mm/sec or more, further preferably 5 mm/sec or more, and further more preferably 10 mm/sec or more.

The basis weight of the second electrode material is 50 to 50 when the thickness of the spacer 2 sandwiched between the current collector 1 and the ion exchange membrane 3 (hereinafter referred to as "spacer thickness") is 0.3 to 3 mm. preferably ^{500g / m 2, 100~400g / m} 2 is more preferable. By controlling the basis weight within the above range, it is possible to prevent the ion exchange membrane 3 from being damaged while ensuring liquid permeability. In particular, in recent years, from the viewpoint of lowering the resistance, the thickness of the ion exchange membrane 3 tends to be thin, and a treatment and a use method for reducing damage to the ion exchange membrane 3 are extremely important. From the above viewpoint, it is more preferable to use, as the second electrode material, a nonwoven fabric or paper whose one surface is flattened, as a base material. As the flattening method, any known method can be applied, and examples thereof include a method of coating the slurry on one side of the carbonaceous fiber and drying; a method of impregnating and drying on a smooth film such as PET.

The thickness of the second electrode material is preferably at least larger than the spacer thickness. For example, when a carbon fiber having a low density such as a non-woven fabric is used and graphite particles or a binding carbonaceous material used for the second electrode material are carried on the carbon fiber, the spacer thickness of 1.5 to It is preferably 6.0 times. However, if the thickness is too thick, the ion-exchange membrane 3 may break through due to the compressive stress of the sheet material, so it is recommended to use a ^second electrode material having a compressive stress of 9.8 N/cm ² or less. preferable. In order to adjust the compressive stress and the like in accordance with the basis weight and thickness of the second electrode material, the second electrode material may be used in a laminated form of 2 layers or 3 layers. Alternatively, a combination with another form of electrode material is also possible.

The second electrode material, BET specific surface area determined from nitrogen adsorption amount is preferably 8m ² / g greater, 10 m ² / g or more is more preferable. When the BET specific surface area is 8 m ² /g or less, the desired low resistance cannot be obtained due to the reduced exposure of the edge surface of the graphite particles (B) and the reduced contact area with the electrolytic solution. The upper limit of the BET specific surface area is not particularly limited from the above viewpoint, but considering the oxidation resistance and the like, it is preferably about 150 m ² /g or less.

[II-3. Second carbon electrode material manufacturing method]
Next, a method of manufacturing the second electrode material will be described. The second electrode material is manufactured through carbonization process, graphitization process, and oxidation treatment process after attaching graphite particles and carbonaceous material precursor (before carbonization) to carbonaceous fiber (base material). can do. A known method can be arbitrarily applied to each step.

Each step will be described below.

(Step of attaching graphite particles and carbonaceous material precursor to carbonaceous fiber)
First, graphite particles and a precursor of a carbonaceous material are attached to carbonaceous fibers. In order to attach the graphite particles and the precursor of the carbonaceous material to the carbonaceous fiber, any known method can be adopted. For example, there is a method in which the above-mentioned carbonaceous material precursor is heated and melted, graphite particles are dispersed in the obtained melt, the carbonaceous fiber is immersed in this melt dispersion, and then cooled to room temperature. Alternatively, as shown in Examples described later, the above carbonaceous material precursor and graphite particles are added to a solvent such as water or alcohol to which a binder (temporary adhesive) that disappears during carbonization such as polyvinyl alcohol is added. A method of dispersing and immersing the carbonaceous fiber in this dispersion and then heating and drying can be used. Here, the excess liquid of the molten dispersion liquid or the dispersion liquid in which the carbonaceous fiber is immersed, is squeezed the excess dispersion liquid when immersed in the dispersion liquid by passing through a nip roller provided with a predetermined clearance, Alternatively, it can be removed by a method such as scratching the surface of the excess dispersion liquid when it is immersed in the dispersion liquid with a doctor blade or the like.

Then, it is dried in an air atmosphere, for example, at 80 to 150°C.

(Carbonization process)
The carbonization step is performed for firing the product after the impregnation obtained in the above step. As a result, the carbonaceous fibers are bound to each other via the graphite particles. In the carbonization step, it is preferable to sufficiently remove the decomposition gas at the time of carbonization, and for example, it is preferable to heat at a temperature of 800° C. or higher and 2000° C. or lower under an inert atmosphere (preferably under a nitrogen atmosphere). The heating temperature is more preferably 1000° C. or higher, further preferably 1200° C. or higher, further preferably 1300° C. or higher, further preferably 1500° C. or lower, further preferably 1400° C. or lower.

As described above, the treatment corresponding to the carbonization step may be performed after the fiber is made flame resistant, but the carbonization treatment performed after the fiber is made flame resistant may be omitted. That is, the method for producing the second electrode material is roughly classified into the following method 1 and method 2.
・Method 1: Fiber flame resistance→fiber carbonization→graphite particles and carbonaceous material impregnation→carbonization→graphitization→oxidation Method 2: fiber flame resistance→graphite particles and carbonaceous material impregnation→carbonization → Graphitization → Oxidation According to the above method 1, although carbonization is performed twice, the processing cost is increased, but the sheet used as the electrode material is not easily affected by the difference in volume shrinkage ratio, and thus the obtained sheet is deformed. There is an advantage that it is difficult to generate (warpage). On the other hand, according to the method 2, although the carbonization step may be performed once, the processing cost can be reduced, but the sheet obtained is easily deformed due to the difference in the volume contraction ratio of each material at the time of carbonization. Which of the above methods 1 and 2 should be adopted may be appropriately determined in consideration of these.

(Graphitization process)
The graphitization step is a step performed to sufficiently enhance the crystallinity of the carbonaceous material, improve the electron conductivity, and improve the oxidation resistance to a sulfuric acid solution in the electrolytic solution. After the carbonization step, it is preferable to further heat at a temperature of 1300° C. or higher in an inert atmosphere (preferably under a nitrogen atmosphere), which is higher than the heating temperature in the carbonization step, 1500° C. or higher. Is more preferable. Note that the upper limit is preferably 2000° C. or lower in consideration of imparting high affinity for the electrolytic solution to the carbonaceous material.
On the other hand, Patent Document 4 described above is different from the second electrode material manufacturing method in that the graphitization step is not performed.

(Oxidation process)
After the above graphitization step, by further performing an oxidation treatment step, oxygen functional groups such as hydroxyl groups, carbonyl groups, quinone groups, lactone groups, and free radical oxides are introduced on the surface of the electrode material. Become. As a result, the above-mentioned O/C ratio≧1% can be achieved. Since these oxygen functional groups greatly contribute to the electrode reaction, sufficiently low resistance can be obtained. Also, the water flow rate can be increased.

As the oxidation treatment process, various treatment processes such as wet chemical oxidation, electrolytic oxidation, and dry oxidation can be applied, but the dry oxidation treatment process is preferable from the viewpoint of processability and manufacturing cost. The dry oxidation treatment step means a step of heating (oxidation treatment) at 500° C. or higher and 900° C. or lower in an air atmosphere. In order to effectively exert the effect of introducing the oxygen functional group, the heating temperature is more preferably 600° C. or higher, further preferably 650° C. or higher. Moreover, 800° C. or lower is more preferable, and 750° C. or lower is further preferable.

Further, in the dry oxidation treatment step, from the viewpoint of maintaining the mechanical strength of the electrode material, it is preferable to adjust the mass yield of the electrode material before and after the oxidation treatment to 90% or more and 96% or less. This can be adjusted by, for example, appropriately adjusting the processing time or temperature of dry air oxidation.

[III. Third Carbon Electrode Material According to the Present Invention]
[III-1. Configuration of Third Carbon Electrode Material]
The present inventors conducted studies using carbon particles other than graphite particles in providing a carbon electrode material having a reduced cell resistance during initial charge/discharge. As a result, it was found that when the carbon particles having a small particle size and low crystallinity are used, the reaction surface area is increased, the oxygen functional group is easily added, the reaction activity is increased, and the low resistance is obtained. ..

Specifically, in the third carbon electrode material, as the carbon particles other than the graphite particles, carbon particles satisfying the following requirements (1) and (2) are adopted.
(1) The particle size of the carbon particles (B) other than the graphite particles is 1 μm or less. (2) In the carbon particles (B) other than the graphite particles, the size of the crystallite in the c-axis direction determined by X-ray diffraction is Lc( In the case of B), Lc(B) is 10 nm or less. When carbon particles having a small particle size are used as in the above (1), the reaction surface area becomes large, and the resistance can be lowered. Further, as in the above (2), the carbon particles having low crystallinity are easily introduced with an oxygen functional group and the reaction activity is improved, so that the resistance can be further reduced.

Furthermore, in the third carbon electrode material, as the carbonaceous material (C), a binding carbonaceous material that binds both the carbonaceous fiber (A) and the carbon particles (B) other than the graphite particles, It was decided to use a highly crystalline carbonaceous material for the carbonaceous fiber (A), which satisfies the requirement (3), within the range (4) below.
(3) When the crystallite sizes in the c-axis direction in the carbonaceous fiber (A) and the carbonaceous material (C) obtained by X-ray diffraction are Lc(A) and Lc(C), respectively, Lc( C)/Lc(A) is 1.0 to 5
(4) The mass content of the carbonaceous material (C) is 14.5% or more based on the total amount of the carbonaceous fiber (A), the carbon particles (B) other than the graphite particles, and the carbonaceous material (C). "Bind both carbonaceous fiber (A) and carbon particles (B) other than graphite particles" (in other words, the carbonaceous material used for the third carbon electrode material is not carbonaceous fibers or graphite particles). Acts as a binder for carbon particles) means that the surface and inside of carbon particles other than carbonaceous fibers and graphite particles (including carbon particles other than graphite particles and carbon particles other than graphite particles) are strongly dependent on the carbonaceous material. This means that when the electrode material as a whole is bound, the carbonaceous fiber is covered with the carbonaceous material and the surfaces of the carbon particles other than the graphite particles are exposed.
However, it is preferable that the carbonaceous material after binding does not form a film. Here, "not in a coating state" means that the carbonaceous material (C) does not form a webbed state such as whole footpads or footpads between the carbonaceous fibers (A). This is because when the coating film is formed, the liquid permeability of the electrolytic solution is deteriorated and the reaction surface area of the carbon particles cannot be effectively used.

Here, the difference from the above-mentioned Patent Document 4 will be described. Since the carbonaceous material strongly bonds the carbonaceous fibers and the like through the carbon particles other than the graphite particles, it forms an efficient conductive path between the carbon particles and the carbonaceous fibers. It is necessary to increase the content ratio of the carbonaceous material to the total amount of the carbonaceous material other than the carbonaceous fiber and the graphite particles and the carbonaceous material in order to form the conductive path. Therefore, in the third carbon electrode material, the above content rate is Is 14.5% or more. On the other hand, in the above-mentioned example of Patent Document 4, the carbonaceous material content is at most 14.4%, which is less than that of the third carbon electrode material, and the two are different in this respect. In the first place, in Patent Document 4, the carbonaceous material to be used exerts an action as a partial adhesive, based on the idea that only the portion where the carbonaceous fiber and the carbon fine particles are originally in contact with each other can be fixed (bonded). This is because there is only the recognition that it should be done. Further, in Patent Document 4, although the crystallinity of the carbonaceous material to be bound is not specifically specified, in order to form an excellent conductive path, the crystallinity of the carbonaceous fiber with respect to the carbonaceous fiber like the third electrode material is formed. The use of a carbonaceous material having a high conductivity enhances the electron conductivity, which enables more efficient electron transfer.

Furthermore, the third carbon electrode material satisfies the following requirement (5).
(5) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. Thereby, oxygen atoms can be introduced into the edge surface of carbon or the defect structure portion. As a result, the introduced oxygen atoms are generated on the surface of the electrode material as reactive groups such as carbonyl group, quinone group, lactone group, and free radical type oxides, and these reactive groups greatly contribute to the electrode reaction. However, a sufficiently low resistance can be obtained.

Since the third electrode material is configured as described above, it is possible to obtain a low resistance and inexpensive electrode with enhanced reaction activity.

As described above, the third electrode material 5 uses the carbonaceous fiber (A) as a base material, and carries the carbon particles (B) other than the graphite particles with a highly crystalline carbonaceous material with respect to the carbonaceous fiber (A). It is an electrode material that satisfies the above requirements (1) to (5). Details of each requirement are as follows.

[Carbon fiber (A)]
The carbonaceous fiber used for the third electrode material is a fiber obtained by subjecting a precursor of an organic fiber to a heating carbonization treatment (details will be described later), and 90% by mass or more is composed of carbon. It means a fiber (JIS L 0204-2). As precursors of organic fibers which are raw materials of carbonaceous fibers, acrylic fibers such as polyacrylonitrile; phenol fibers; PBO fibers such as polyparaphenylenebenzobisoxazole (PBO); aromatic polyamide fibers; isotropic pitch fibers, different Pitch fibers such as isotropic pitch fibers and mesophase pitch; cellulose fibers; etc. can be used. Of these, acrylic fiber, phenol fiber, cellulose fiber, isotropic pitch fiber, and anisotropic pitch fiber are preferable as the precursor of the organic fiber, and acrylic fiber is more preferable, from the viewpoint of excellent strength and elastic modulus. The acrylic fiber is not particularly limited as long as it contains acrylonitrile as a main component, but the content of acrylonitrile in the raw material monomer forming the acrylic fiber is preferably 95% by mass or more, and 98% by mass or more. Is more preferable.

The mass average molecular weight of the organic fiber is not particularly limited, but is preferably 10,000 or more and 100,000 or less, more preferably 15,000 or more and 80,000 or less, and further preferably 20,000 or more and 50,000 or less. The mass average molecular weight can be measured by a method such as gel permeation chromatography (GPC) or solution viscosity.

The average fiber diameter of the carbonaceous fibers is preferably 0.5 to 40 μm. If the average fiber diameter is smaller than 0.5 μm, liquid permeability deteriorates. On the other hand, when the average fiber diameter is larger than 40 μm, the reaction surface area of the fiber portion is reduced and the cell resistance is increased. Considering the balance between liquid permeability and reaction surface area, it is more preferably 3 to 20 μm.

In the third electrode material, it is preferable to use the carbonaceous fiber structure as a base material, which improves the strength and facilitates handling and workability. As the structure, specifically, a spun yarn, a filament bundled yarn, a non-woven fabric, a knitted fabric, a woven fabric, a special knitted woven fabric or carbon described in Japanese Patent Laid-Open No. 63-200467, which is a sheet-like product made of carbonaceous fibers. Examples include paper made of fibers. Of these, non-woven fabrics made of carbonaceous fibers, knitted fabrics, woven fabrics, special woven and knitted fabrics, and papers made of carbon fibers are more preferable from the viewpoints of handling, processability, and manufacturability.

When a non-woven fabric, a knitted fabric, a woven fabric or the like is used here, the average fiber length is preferably 30 to 100 mm. When using paper made of carbon fiber, the average fiber length is preferably 5 to 30 mm. Within the above range, a uniform fiber structure can be obtained.

As described above, the carbonaceous fiber is obtained by subjecting an organic fiber precursor to a heating carbonization treatment. The “heating carbonization treatment” includes at least a flameproofing step and a carbonization (firing) step. Is preferred. However, among these, the carbonization step does not necessarily have to be performed after the flameproofing step as described above, and after attaching the graphite particles and the carbonaceous material to the flameproofed fiber as described in Examples described later. A carbonization step may be performed, and in this case, the carbonization step after the flameproofing step can be omitted.

Of these, the flameproofing step means a step of heating the precursor of the organic fiber at a temperature of preferably 180°C or higher and 350°C or lower in an air atmosphere to obtain the flameproofed organic fiber. The heat treatment temperature is more preferably 190° C. or higher, further preferably 200° C. or higher. Further, it is preferably 330° C. or lower, and more preferably 300° C. or lower. By heating in the above temperature range, the content ratio of nitrogen and hydrogen in the organic fiber can be reduced and the carbonization ratio can be improved while the organic fiber is not thermally decomposed and the form of the carbonaceous fiber is maintained. During the flameproofing step, the organic fiber may be thermally shrunk to collapse the molecular orientation, and the conductivity of the carbonaceous fiber may decrease, so it is preferable to subject the organic fiber to flameproofing under tension or stretching. More preferably, the flameproof treatment is performed under tension.

In the carbonization step, the flame-resistant organic fiber obtained as described above is heated at a temperature of preferably 1000° C. or higher and 2000° C. or lower in an inert atmosphere (preferably under a nitrogen atmosphere) to obtain a carbonaceous fiber. Means a process. The heating temperature is more preferably 1100° C. or higher, still more preferably 1200° C. or higher. Further, it is more preferably 1900° C. or lower. By carrying out the carbonization step in the above temperature range, carbonization of the organic fiber proceeds, and a carbonaceous fiber having a pseudo-graphite crystal structure can be obtained.

Since the organic fibers have different crystallinities, the heating temperature in the carbonization step can be selected according to the type of the organic fibers used as the raw material. For example, when an acrylic resin (preferably polyacrylonitrile) is used as the organic fiber, the heating temperature is preferably 800° C. or higher and 2000° C. or lower, and more preferably 1000° C. or higher and 1800° C. or lower.

The flameproofing step and the carbonization step described above are preferably performed continuously, and the rate of temperature rise when raising the temperature from the flameproofing temperature to the carbonization temperature is preferably 20° C./min or less, and more preferably Is 15°C/min or less. By setting the heating rate within the above range, it is possible to obtain a carbonaceous fiber which retains the shape of the organic fiber and is excellent in mechanical properties. The lower limit of the temperature rising rate is preferably 5° C./min or more in consideration of mechanical properties and the like.

As will be described in detail later in the section of carbonaceous material (C), the third electrode material includes carbonaceous fiber (A) and carbonaceous material (C) as defined in (3) above. When the crystallite sizes in the c-axis direction obtained by X-ray diffraction are Lc(A) and Lc(C), respectively, Lc(C)/Lc(A) satisfies 1.0 to 5. .. Therefore, as long as the third electrode material satisfies the above (3), Lc(A) in the carbonaceous fiber (A) is not particularly limited, but Lc(A) is preferably 1 to 6 nm. Thereby, the effects of appropriate electron conductivity, oxidation resistance against sulfuric acid solvent, etc., and easy provision of oxygen functional groups are effectively exhibited. The method for measuring Lc(A) and Lc(C) will be described in detail in the section of Examples below.

[Carbon particles other than graphite particles (B)]
In the third electrode material, "carbon particles other than graphite particles" is useful for increasing the reaction surface area and realizing low resistance. As the third electrode material, a material satisfying the above (1) and (2) was used in order to reduce the resistance.

First, the particle diameter of “carbon particles other than graphite particles” used for the third electrode material is 1 μm or less, and preferably 0.5 μm or less, as defined in the above (1). If the particle size exceeds 1 μm, the reaction surface area becomes small and the resistance increases. Here, the "particle diameter" means an average particle diameter (D50) at a median 50% diameter in a particle diameter distribution obtained by a dynamic light scattering method or the like. As the carbon particles other than the graphite particles, commercially available products may be used, and in that case, the particle size described in the catalog can be adopted. A preferable lower limit is 0.005 μm or more.

The BET specific surface area obtained from the nitrogen adsorption amount of “carbon particles other than graphite particles” used for the third electrode material is preferably 20 m ² /g or more, more preferably 30 m ² /g or more, and 40 m ² /g or more. Is more preferable. If the BET specific surface area is less than 20 m ² /g, the edge exposure of the carbon particles is reduced and the contact area with the electrolytic solution is also reduced, so that the desired low resistance cannot be obtained. Although the upper limit is not particularly limited from the above viewpoint, considering that particles having a large surface area and bulky tend to increase the viscosity of the dispersion solution and deteriorate the processability into a sheet or the like, it is generally 2000 m ² /g. The following is preferable. Here, the “BET specific surface area obtained from the amount of adsorbed nitrogen” means a specific surface area calculated from the amount of gas molecules adsorbed by adsorbing nitrogen molecules on solid particles.

Furthermore, Lc(B) in the "carbon particles other than the graphite particles" used for the third electrode material is 10 nm or less as specified in (2) above. When highly crystalline carbon particles having an Lc(B) of more than 10 nm are used, it is difficult to introduce oxygen functional groups, so that the affinity in the vicinity of the carbon particles with respect to the aqueous electrolytic solution decreases, the reaction activity decreases, and the resistance increases. To do. It is preferably 6 nm or less. The lower limit is not particularly limited from the above viewpoint, but considering the oxidation resistance to the electrolytic solution and the like, it is preferably about 0.5 nm or more. The method for measuring Lc(B) and La(B) will be described in detail in the section of Examples below.

Examples of the “carbon particles other than graphite particles” used for the third electrode material include, for example, acetylene black (acetylene soot), oil black (furnace black, oil soot), ketjen black, gas black (gas soot). Such as carbon blacks such as )) having high reactivity and high specific surface area and low crystallinity are often used. Other than the above, carbon nanotube (CNT, carbon nanotube), carbon nanofiber, carbon aerogel, mesoporous carbon, graphene, graphene oxide, N-doped CNT, boron-doped CNT, fullerene and the like can be mentioned. Carbon blacks are preferably used from the viewpoint of raw material cost and the like.

The content of “carbon particles other than graphite particles” used in the third electrode material is the total of the above-mentioned carbonaceous fibers (A), carbon particles other than graphite particles (B), and carbonaceous material (C) described later. The mass ratio to the amount is preferably 5% or more, more preferably 10% or more. As a result, the carbon particles other than the graphite particles are bound by the carbonaceous material, and the resistance decreases. However, when the amount of the carbon particles (B) other than the graphite particles is excessive, the binding property due to the carbonaceous material becomes insufficient, particles are dropped, and the liquid permeability is deteriorated due to the improvement of the packing density. The desired low resistance cannot be obtained. Therefore, the upper limit is preferably 90% or less. The content of the carbonaceous fiber (A) used for calculating the content is the content of the structure when a structure such as a nonwoven fabric is used as the base material.

In the third electrode material, the mass ratio of the carbonaceous material (C) described below to the carbon particles (B) other than the graphite particles is preferably 0.2 or more and 10 or less, and 0.3 or more and 7 or less. More preferably. When the ratio is less than 0.2, carbon particles other than the graphite particles are more likely to fall off, and the carbon particles are not sufficiently bound to the carbonaceous material. On the other hand, when the above ratio exceeds 10, the carbon edge surface of the carbon particles, which is the reaction field, is covered, and the desired low resistance cannot be obtained.

[Carbonaceous material (C)]
In the third electrode material, the carbonaceous material is originally added as a binder (binder) for strongly binding the carbonaceous fibers that cannot be bound to the carbon particles other than the graphite particles. .. In the third electrode material, the size of the crystallite in the c-axis direction obtained by X-ray diffraction in the carbonaceous fiber (A) and the carbonaceous material (C) as defined in (3) above is Lc( When A) and Lc(C) are used, Lc(C)/Lc(A) needs to satisfy 1.0 to 5.
By using the highly crystalline binding carbonaceous material for the carbonaceous fiber (A), the electron conduction resistance between the carbon particles (B) and the carbonaceous fiber (A) is lowered, The electron conduction path between the carbon particles (B) and the carbonaceous fibers (A) becomes smooth. In addition, since the carbonaceous material strongly bonds between the carbonaceous fibers via the carbon particles other than the graphite particles, an efficient conductive path can be formed, and the resistance reducing action by the addition of the carbon particles other than the above-mentioned graphite particles is possible. It has been found that is more effectively exhibited.

If the ratio of Lc(C)/Lc(A) is less than 1.0, the above effect is not effectively exhibited. The above ratio is preferably 1.5 or more, more preferably 3.0 or more. On the other hand, when the above ratio exceeds 5, it becomes difficult to give oxygen functional groups to the carbonaceous material portion. The above ratio is preferably 4.5 or less, more preferably 4.0 or less.

In the third electrode material, the range of Lc(C) is not particularly limited as long as the ratio of Lc(C)/Lc(A) satisfies the above range, but from the viewpoint of further lowering the resistance, Lc(C) Is preferably 10 nm or less, more preferably 7.5 nm or less. The lower limit of Lc(C) is not particularly limited from the above viewpoint, but in consideration of electron conductivity and the like, it is preferably about 3 nm or more.

The content of the carbonaceous material (C) used in the third electrode material is the mass ratio with respect to the total amount of the carbonaceous fiber (A) and the carbon particles (B) other than the graphite particles, and the carbonaceous material (C). Is 14.5% or more, preferably 15% or more, and more preferably 17% or more. By increasing the content ratio of the carbonaceous material in this way, both the carbonaceous fiber and the carbon particles other than the graphite particles can be sufficiently bound, and the binding action by the addition of the carbonaceous material is effectively exhibited. The upper limit is preferably about 90% or less in consideration of the liquid permeability of the electrolytic solution.

The carbonaceous material (C) used for the third electrode material may be of any type as long as it can bind carbon particles other than the carbonaceous fiber (A) and the graphite particles (B), and specifically, There is no particular limitation as long as it exhibits binding properties when carbonized during the production of the third electrode material. Examples thereof include pitches such as coal tar pitch and coal pitch; phenol resin, benzoxazine resin, epoxide resin, furan resin, vinyl ester resin, melanin-formaldehyde resin, urea-formaldehyde resin, resorcinol-formaldehyde. Resin, cyanate ester resin, bismaleimide resin, polyurethane resin, resin such as polyacrylonitrile; furfuryl alcohol; rubber such as acrylonitrile-butadiene rubber. You may use a commercial item for these.

Of these, particularly easily crystallizable pitches such as coal tar pitch and coal pitch are preferable because the target carbonaceous material (C) can be obtained at a low firing temperature. Further, a phenol resin is also preferably used because the increase or decrease in crystallinity due to the firing temperature is small and the crystallinity is easily controlled. Further, a polyacrylonitrile resin is also preferably used because the intended carbonaceous material (C) can be obtained by raising the firing temperature. Particularly preferred are pitches.
According to the preferable mode of the third electrode material, since the phenol resin is not used, the harmful effects (formaldehyde generation and formaldehyde odor at room temperature) due to the phenol resin do not occur, and there is an advantage that no odor is generated at room temperature. On the other hand, in Patent Document 4 described above, since the phenol resin is used as the adhesive, in addition to the above-mentioned adverse effects, equipment for controlling the formaldehyde concentration at the work place below the control concentration is additionally required There is a disadvantage in terms of work.

Here, the pitches that are particularly preferably used will be described in detail. The content rate of the mesophase phase (liquid crystal phase) of the above-mentioned coal tar pitch or coal-based pitch can be controlled by the temperature and time of the infusibilizing treatment. When the content of the mesophase phase is small, it can be obtained by melting at a relatively low temperature or in a liquid state at room temperature. On the other hand, when the content of the mesophase phase is high, the mesophase phase is melted at a high temperature and a high carbonization yield is obtained. When the pitches are applied to the carbonaceous material (C), the mesophase phase content is preferably high (that is, the carbonization rate is high), for example, 30% or more is preferable, and 50% or more is more preferable. Thereby, the fluidity at the time of melting can be suppressed, and the carbonaceous fibers can be bound through the carbon particles without excessively covering the surfaces of the carbon particles other than the graphite particles. The upper limit is preferably, for example, 90% or less in consideration of the expression of binding property.

From the same viewpoint as above, the melting point of the pitches is preferably 100° C. or higher, and more preferably 200° C. or higher. Thereby, in addition to the above effects, the odor during the attachment process can be suppressed, which is also preferable in terms of processability. The upper limit is preferably, for example, 350° C. or lower in consideration of the expression of binding property.

[III-2. Characteristics of third carbon electrode material]
In the third electrode material, the number of bonded oxygen atoms on the surface of the carbon electrode material satisfies 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. Hereinafter, the ratio of the number of bonded oxygen atoms to the total number of carbon atoms may be abbreviated as O/C. O/C can be measured by surface analysis such as X-ray photoelectron spectroscopy (XPS) and fluorescent X-ray analysis.

By using an electrode material having O/C of 1% or more, the electrode reaction rate can be remarkably increased, and a low resistance can be obtained. Further, the hydrophilicity can be enhanced by controlling the O/C, and the water flow rate (preferably 0.5 mm/sec or more) of the electrode material described later can be secured. On the other hand, when an electrode material having a low oxygen concentration of O/C of less than 1% is used, the electrode reaction rate at the time of discharge becomes low, and the electrode reaction activity cannot be increased. As a result, the resistance increases. Although the details of the reason why the electrode reaction activity (in other words, voltage efficiency) is improved by using the electrode material in which a large number of oxygen atoms are bonded to the surface of the electrode material are not clear, the oxygen atoms existing on the surface in many cases are carbonaceous. It is considered that this is because it is effectively acting on the affinity between the material (C) and the electrolytic solution, transfer of electrons, desorption of complex ions from the carbonaceous material, complex exchange reaction, and the like.

The third electrode material has excellent hydrophilicity. The hydrophilicity can be confirmed by the water flow rate when water drops are dripped after the electrode material is subjected to the dry oxidation treatment. The water flow rate of the third electrode material is preferably 0.5 mm/sec or more. From this, it can be determined that it has a sufficient affinity for the electrolytic solution. The higher the water flow rate of the electrode material is, the more preferable it is, more preferably 1 mm/sec or more, further preferably 5 mm/sec or more, and further more preferably 10 mm/sec or more.

The weight of the third electrode material is 50 to 50 when the thickness of the spacer 2 sandwiched between the current collector 1 and the ion exchange membrane 3 (hereinafter referred to as "spacer thickness") is 0.3 to 3 mm. preferably ^{500g / m 2, 100~400g / m} 2 is more preferable. By controlling the basis weight within the above range, it is possible to prevent the ion exchange membrane 3 from being damaged while ensuring liquid permeability. In particular, in recent years, from the viewpoint of lowering the resistance, the thickness of the ion exchange membrane 3 tends to be thin, and a treatment and a use method for reducing damage to the ion exchange membrane 3 are extremely important. From the above viewpoint, it is more preferable to use, as the third electrode material, a non-woven fabric or paper whose one surface is flattened, as a base material. As the flattening method, any known method can be applied, and examples thereof include a method of coating the slurry on one side of the carbonaceous fiber and drying; a method of impregnating and drying on a smooth film such as PET.

The thickness of the third electrode material is preferably at least larger than the spacer thickness. For example, when a carbon fiber having a low density such as a non-woven fabric is used and carbon particles other than the graphite particles used for the third electrode material or a binding carbonaceous material is carried on the carbon fiber, the spacer thickness It is preferably 1.5 to 6.0 times. However, if the thickness is too thick, the ion-exchange membrane 3 may break through due to the compressive stress of the sheet material, so it is recommended to use a third electrode material having a compressive stress of 9.8 N/cm ² or less. preferable. In order to adjust the compressive stress and the like in accordance with the basis weight and thickness of the third electrode material, it is possible to use the third electrode material in a laminated manner such as two layers or three layers. Alternatively, a combination with another form of electrode material is also possible.

The BET specific surface area of the third electrode material, which is determined from the amount of adsorbed nitrogen, is preferably 0.5 m ² /g or more, more preferably 1 m ² /g or more. When the BET specific surface area is less than 0.5 m ² /g, the desired low resistance cannot be obtained due to the decrease in the exposure of the edge surface of the carbon particles (B) other than the graphite particles and the decrease in the contact area with the electrolytic solution. .. The upper limit of the BET specific surface area is not particularly limited from the above viewpoint, but in consideration of the formation of conductive paths between particles, the adhesiveness of carbon particles other than graphite particles to fibers, etc., it is generally 1500 m ² /g or less. Preferably.

The third electrode material is useful as an electrode material for a redox flow battery, and the type of electrolytic solution is not particularly limited. Therefore, it is possible to use not only a metal-based electrolytic solution such as a vanadium-based electrolytic solution and a Mn/Ti-based electrolytic solution, but also another metal-based electrolytic solution or a non-metal-based electrolytic solution. Examples of the metal-based electrolytic solution include active materials such as Ti, V, Cr, Mn, Fe, Cr, Cu, Zn, and Ce. Examples of the non-metal electrolyte include Cl ₂ , Br ₂ , I ₂ , H ₂ and O ₂ as well as organic molecules such as polyacid and quinone flavin; organic compounds such as TEMPO (tetramethylpiperidinyloxy radical) Examples include active materials such as molecular radicals.

[III-3. Third carbon electrode material manufacturing method]
Next, a method of manufacturing the third electrode material will be described. The third electrode material is obtained by impregnating carbon particles other than graphite particles with carbonaceous fibers (base material) and a precursor of carbonaceous material (before carbonization), followed by carbonization step, graphitization step, and oxidation treatment. It can be manufactured through steps. A known method can be arbitrarily applied to each step.

Each step will be described below.

(Step of attaching carbon particles other than graphite particles and carbonaceous material precursors to carbonaceous fiber)
First, carbon particles other than graphite particles and a precursor of a carbonaceous material are attached to carbonaceous fibers. A known method can be arbitrarily adopted to attach the carbon particles other than the graphite particles and the precursor of the carbonaceous material to the carbonaceous fiber. For example, a method of heating and melting the above carbonaceous material precursor, dispersing carbon particles other than graphite particles in the obtained melt, immersing carbonaceous fiber in this melt dispersion, and then cooling to room temperature Is mentioned. Alternatively, as shown in Examples described later, water or alcohol obtained by adding a binder (temporary adhesive), such as polyvinyl alcohol, which disappears at the time of carbonization, to carbon particles other than the above carbonaceous material precursor and graphite particles. It is possible to use a method in which the carbonaceous fiber is dispersed in a solvent such as, and the carbonaceous fiber is immersed in this dispersion, and then heated and dried. Here, the excess liquid of the molten dispersion liquid or the dispersion liquid in which the carbonaceous fiber is immersed, is squeezed the excess dispersion liquid when immersed in the dispersion liquid by passing through a nip roller provided with a predetermined clearance, Alternatively, it can be removed by a method such as scratching the surface of the excess dispersion liquid when it is immersed in the dispersion liquid with a doctor blade or the like.

Then, it is dried in an air atmosphere, for example, at 80 to 150°C.

(Carbonization process)
The carbonization step is performed for firing the product after the impregnation obtained in the above step. As a result, the carbonaceous fibers are bound through the carbon particles other than the graphite particles. In the carbonization step, it is preferable to sufficiently remove the decomposition gas at the time of carbonization, and for example, it is preferable to heat at a temperature of 800° C. or higher and 2000° C. or lower under an inert atmosphere (preferably under a nitrogen atmosphere). The heating temperature is more preferably 1000° C. or higher, further preferably 1200° C. or higher, further preferably 1300° C. or higher, further preferably 1500° C. or lower, further preferably 1400° C. or lower.

As described above, the treatment corresponding to the carbonization step may be performed after the fiber is made flame resistant, but the carbonization treatment performed after the fiber is made flame resistant may be omitted. That is, the method of manufacturing the third electrode material is roughly classified into the following method 1 and method 2.
・Method 1: Carbonization of fibers → Carbonization of fibers → Impregnation of carbon particles and carbonaceous materials other than graphite particles → Carbonization → Graphitization → Oxidation ・ Method 2: Flame resistance of fibers → Carbon particles other than graphite particles and Carbonaceous material impregnation → carbonization → graphitization → oxidation According to the above method 1, although carbonization is performed twice, the processing cost increases, but the sheet used as an electrode material is affected by the difference in volume shrinkage ratio. Since it is difficult, the obtained sheet has an advantage that it is difficult to deform (warp). On the other hand, according to the method 2, although the carbonization step may be performed once, the processing cost can be reduced, but the sheet obtained is easily deformed due to the difference in the volume contraction ratio of each material at the time of carbonization. Which of the above methods 1 and 2 should be adopted may be appropriately determined in consideration of these.

(Graphitization process)
The graphitization step is a step performed to sufficiently enhance the crystallinity of the carbonaceous material, improve the electron conductivity, and improve the oxidation resistance to a sulfuric acid solution in the electrolytic solution. After the carbonization step, it is preferable to further heat at a temperature of 1300° C. or higher in an inert atmosphere (preferably under a nitrogen atmosphere) and higher than the heating temperature of the carbonization step, 1500 C. or higher is more preferable. Note that the upper limit is preferably 2000° C. or lower in consideration of imparting high affinity for the electrolytic solution to the carbonaceous material.
On the other hand, Patent Document 4 described above is different from the second electrode material manufacturing method in that the graphitization step is not performed.

(Oxidation process)
After the above graphitization step, by further performing an oxidation treatment step, oxygen functional groups such as hydroxyl groups, carbonyl groups, quinone groups, lactone groups, and free radical oxides are introduced on the surface of the electrode material. Become. As a result, the above-mentioned O/C ratio≧1% can be achieved. Since these oxygen functional groups greatly contribute to the electrode reaction, sufficiently low resistance can be obtained. Also, the water flow rate can be increased.

As the oxidation treatment process, various treatment processes such as wet chemical oxidation, electrolytic oxidation, and dry oxidation can be applied, but the dry oxidation treatment process is preferable from the viewpoint of processability and manufacturing cost. The dry oxidation treatment step means a step of heating (oxidation treatment) at 500° C. or higher and 900° C. or lower in an air atmosphere. In order to effectively exert the effect of introducing the oxygen functional group, the heating temperature is more preferably 600° C. or higher, further preferably 650° C. or higher. Moreover, 800° C. or lower is more preferable, and 750° C. or lower is further preferable.

Further, in the dry oxidation treatment step, from the viewpoint of maintaining the mechanical strength of the electrode material, it is preferable to adjust the mass yield of the electrode material before and after the oxidation treatment to 90% or more and 96% or less. This can be adjusted by, for example, appropriately adjusting the processing time or temperature of dry air oxidation.

The present application includes Japanese patent application No. 2017-172133 filed on September 7, 2017, Japanese patent application No. 2017-172134 filed on the same day, Japanese patent application No. 2017- filed on the same day. Claims the benefit of priority under 172135. Japanese patent application No. 2017-172133 filed on September 7, 2017, Japanese patent application No. 2017-172134 filed on the same day, Japanese patent application No. 2017-172135 filed on the same day The entire contents of the specification are incorporated herein by reference.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. The present invention is not limited to the examples below. In the following,% means “mass %” unless otherwise specified.

In this example, the following items were measured. The details of the measuring method are as follows.

(1) Measurement of crystallite size (Lc) in the c-axis direction by X-ray diffraction (1-1) First electrode material Lc(A) and carbonaceous material of carbonaceous fiber in the first electrode material Lc(B) of the material was measured as follows.
The same heat treatment as in Example 1 was sequentially performed on each of the carbonaceous fibers and the carbonaceous material used in this example (simple substance), and the final treated sample was used for measurement. Basically, it is considered that the crystallinity of carbon is dominated by the effect of thermal energy given to the sample, and the thermal history of the highest temperature given to the sample determines the crystallinity of Lc, but it depends on the degree of subsequent oxidation treatment. Is likely to disturb the graphene laminated structure formed during the graphitization process, resulting in a decrease in crystallinity due to generation of a defect structure or the like. Therefore, the final processed sample was used.

Each single sample collected as described above was ground in an agate mortar to a particle size of about 10 μm. Approximately 5% by mass of high-purity silicon powder for X-ray standard is mixed as an internal standard substance to the crushed sample, packed in a sample cell, and wide-angle X-ray is measured by the diffractometer method using CuKα ray as a radiation source. did.

For the carbonaceous fiber (A) and the carbonaceous material (B) used for the first electrode material, their Lc values were calculated by performing peak separation from the chart obtained by the above wide-angle X-ray measurement. Specifically, the peak having a vertex in the range of 25.3° to 25.7°, which is twice the diffraction angle θ (2θ), was used as the carbonaceous material (B). After determining the peak shape as a sine wave from each peak top, the peak shape as a sine wave was determined from the skirt portion seen in the vicinity of 24.0° to 25.0°, and the carbon fiber (A ). From the two peaks separated by the above method, each Lc was calculated by the following method.

For the correction of the curve, the following simple method was used without correcting the so-called Lorentz factor, polarization factor, absorption factor, atomic scattering factor and the like. That is, the actual intensity from the baseline of the peak corresponding to <002> diffraction was re-plotted to obtain a <002> corrected intensity curve. From the length of the line segment (half-width β) at which the line parallel to the angle axis drawn to half the height of this peak intersects with the above correction intensity curve, the size of the crystallite in the c-axis direction is calculated by the following formula. Lc was calculated.

Lc=(k·λ)/(β·cos θ)
Here, the structure coefficient k=0.9, the wavelength λ=1.5418Å, β is the half width of the <002> diffraction peak, and θ is the <002> diffraction angle.

(1-2) Second Electrode Material Lc(A) of carbonaceous fibers, Lc(B) of graphite particles, and Lc(C) of carbonaceous material in the second electrode material were measured as follows. did.
Each of the carbonaceous fibers, graphite particles, and carbonaceous material (single body) used in this example was subjected to the same heat treatment as in Example 2 in order, and the final treated sample was used for measurement. Basically, it is considered that the crystallinity of carbon is dominated by the effect of thermal energy given to the sample, and the thermal history of the highest temperature given to the sample determines the crystallinity of Lc, but it depends on the degree of subsequent oxidation treatment. Is likely to disturb the graphene laminated structure formed during the graphitization process, resulting in a decrease in crystallinity due to generation of a defect structure or the like. Therefore, the final processed sample was used.

Each single sample collected as described above was ground in an agate mortar to a particle size of about 10 μm. Approximately 5% by mass of high-purity silicon powder for X-ray standard is mixed as an internal standard substance to the crushed sample, packed in a sample cell, and wide-angle X-ray is measured by the diffractometer method using CuKα ray as a radiation source. did.

The carbonaceous fiber (A) and the graphite particles (B) used for the second electrode material, and the carbonaceous material (C) binding these are subjected to peak separation from the chart obtained by the wide-angle X-ray measurement. Thus, the Lc value of each was calculated. Specifically, the peak whose peak is seen in the range of 26.4° to 26.6° when twice the diffraction angle θ (2θ) is in the range of 25.3° to 25.7° is graphite particles (B). The peak at which the peak was observed was designated as carbonaceous material (C). After determining the peak shape as a sine wave from each peak top, the peak shape as a sine wave was determined from the skirt portion seen in the vicinity of 24.0° to 25.0°, and the carbon fiber (A ).
From the three peaks separated by the above method, each Lc was calculated by the following method.

For the correction of the curve, the following simple method was used without correcting the so-called Lorentz factor, polarization factor, absorption factor, atomic scattering factor and the like. That is, the actual intensity from the baseline of the peak corresponding to <002> diffraction was re-plotted to obtain a <002> corrected intensity curve. From the length of the line segment (half-width β) at which the line parallel to the angle axis drawn to half the height of this peak intersects with the above correction intensity curve, the size of the crystallite in the c-axis direction is calculated by the following formula. Lc was calculated.

Lc=(k·λ)/(β·cos θ)
Here, the structure coefficient k=0.9, the wavelength λ=1.5418Å, β is the half width of the <002> diffraction peak, and θ is the <002> diffraction angle.

(1-3) Third Electrode Material Lc(A) of carbonaceous fiber, Lc(B) and La(B) of carbon particles other than graphite particles, Lc(C of carbonaceous material in the third electrode material ) Was measured as follows.
Each of the carbonaceous fibers, carbon particles other than graphite particles, and carbonaceous material (single body) used in this example was subjected to the same heat treatment as in Example 3 in order, and the final treated sample was used for measurement. Basically, it is considered that the crystallinity of carbon is dominated by the effect of thermal energy given to the sample, and the thermal history of the highest temperature given to the sample determines the crystallinity of Lc, but it depends on the degree of subsequent oxidation treatment. Is likely to disturb the graphene laminated structure formed during the graphitization process, resulting in a decrease in crystallinity due to generation of a defect structure or the like. Therefore, the final processed sample was used.

Each single sample collected as described above was ground in an agate mortar to a particle size of about 10 μm. Approximately 5% by mass of high-purity silicon powder for X-ray standard is mixed as an internal standard substance with the crushed sample, packed in a sample cell, and CuKα rays are used as the radiation source to measure wide-angle X-rays by the diffractometer method. did.

The carbonaceous fiber (A) and the carbon particles (B) other than the graphite particles used for the third electrode material, and the carbonaceous material (C) binding these are shown in the chart obtained by the wide-angle X-ray measurement. By performing peak separation, each Lc value was calculated. Specifically, a peak having an apex in the range of 26.4° to 26.6°, which is twice the diffraction angle θ (2θ), is a carbon particle (B) other than graphite particles, 25.3° to 25. The peak having a peak in the range of 7° was designated as carbonaceous material (C). After determining the peak shape as a sine wave from each peak top, the peak shape as a sine wave was determined from the skirt portion seen around 24.0° to 25.0°, and the carbon fiber (A ). From the three peaks separated by the above method, each Lc was calculated by the following method.

For the correction of the curve, the following simple method was used without correcting the so-called Lorentz factor, polarization factor, absorption factor, atomic scattering factor and the like. That is, the actual intensity from the baseline of the peak corresponding to <002> diffraction was re-plotted to obtain a <002> corrected intensity curve. From the length of the line segment (half-width β) at which the line parallel to the angle axis drawn to half the height of this peak intersects with the above correction intensity curve, the size of the crystallite in the c-axis direction is calculated by the following formula. Lc was calculated.

Lc=(k·λ)/(β·cos θ)
Here, the structure coefficient k=0.9, the wavelength λ=1.5418Å, β is the half width of the <002> diffraction peak, and θ is the <002> diffraction angle.

(2) Measurement of O/C by XPS surface analysis For measurement of X-ray photoelectron spectroscopy, which is abbreviated as ESCA or XPS, an apparatus of ULVAC-PHI 5801MC was used.
First, the sample was fixed on a sample holder with a Mo plate, sufficiently evacuated in a preliminary exhaust chamber, and then put into the chamber of the measurement chamber. Monochrome AlKα rays were used as the radiation source, the output was 14 kV and 12 mA, and the vacuum degree in the apparatus was 10 ⁻⁸ torr.
An all-elements scan was performed to examine the composition of surface elements, a narrow scan was performed for the detected and expected elements, and the abundance ratio was evaluated.
The ratio of the number of surface-bound oxygen atoms to the total number of surface carbon atoms was calculated as a percentage (%), and O/C was calculated.

(3) Charge/Discharge Test Each electrode material obtained by the method described below was cut into an electrode area of 16 cm ² of 10 cm in the vertical direction (liquid passing direction) and 1.6 cm in the width direction, and the cell of FIG. 1 was assembled. As the ion exchange membrane, Nafion 212 membrane was used.
Here, one piece of the first electrode material is used for each of the felt base materials (Nos. 1 to 2 and 5 to 9) described below, and each of the spun lace (No. 4) and the paper base material (No. 3) is used. Two sheets are arranged in the positive and negative electrodes, and the filling rate of the electrode material in the cell is 0.1 to 0.2 g/cc for the felt base material and 0.3 to 0. 0 for the carbon paper base material and the spunlace base material. The spacer thickness was adjusted to be 4 g/cc. The reason for changing the filling rate in the cell for each base material used in this way is that carbon paper and spunlace have a thin base material thickness and are easily highly filled. Is insufficient and the contact resistance between the electrode material and the current collector plate increases. As a specific spacer thickness, the felt base material (Nos. 1 to 2 and 5 to 9) described later has 2.5 mm, the spunlace base material (No. 4) has 1.0 mm, and the paper base material (No. 3). Was 0.5 mm.

Further, one second electrode material is used for each of the felt base materials (Nos. 1 to 3 and 6 to 10) described later, and two each for the spun lace (No. 5) and the paper base material (No. 4). Sheets are arranged for the positive electrode and the negative electrode, and the filling rate of the electrode material in the cell is 0.1 to 0.2 g/cc for the felt base material and 0.3 to 0.4 g for the carbon paper base material and the spunlace base material. The spacer thickness was adjusted to be /cc. The reason for changing the filling rate in the cell for each base material used in this way is that carbon paper and spunlace have a thin base material thickness and are easily highly filled. Is insufficient and the contact resistance between the electrode material and the current collector plate increases. As a specific spacer thickness, 2.5 mm for felt base materials (Nos. 1 to 3 and 6 to 10) described later, 1.0 mm for spunlace base material (No. 5), and paper base material (No. 4). Was 0.5 mm.

Also, one third electrode material is arranged for each of the positive electrode and the negative electrode, and the filling rate of the electrode material in the cell is 0.1 to 0.2 g/cc for the felt base material, the carbon paper base material and the spun lace. In the base material, the spacer thickness was adjusted to be 0.3 to 0.4 g/cc. The reason for changing the filling rate in the cell for each base material used in this way is that carbon paper and spunlace have a thin base material thickness and are easily highly filled. Is insufficient and the contact resistance between the electrode material and the current collector plate increases.

Then, the total cell resistance was calculated from the voltage curve after 10 cycles at a voltage range of 1.70 to 1.00 V at 100 mA/cm ² by the following formula. A 2.0 mol/L vanadium oxysulfate aqueous solution of 2.5 moL/L sulfuric acid was used for the positive electrode electrolyte, and a 2.0 moL/L vanadium sulfate 2.5 moL/L sulfuric acid aqueous solution was used for the negative electrode electrolyte. .. The amount of electrolyte was set to a large excess with respect to the cell and piping. The liquid flow rate was 10 mL/min, and the measurement was performed at 30°C. The charging voltage V _C50 and the discharging voltage V _D50 corresponding to the amount of electricity when the charging rate is 50% are obtained from the voltage curves, the current density is I (mA/cm ² ), and the total cell resistance (Ω· cm ² ) was calculated.

ここで、
Ｖ_C50は、充電率が５０％のときの電気量に対する充電電圧を電極曲線から求めたもの、
Ｖ_D50は、充電率が５０％のときの電気量に対する放電電圧を電極曲線から求めたもの、
Ｉ＝電流密度（ｍＡ／ｃｍ²）

here,
V _C50 is a value obtained by obtaining the charging voltage with respect to the amount of electricity when the charging rate is 50% from the electrode curve,
V _D50 is a value obtained by calculating the discharge voltage with respect to the amount of electricity when the charging rate is 50% from the electrode curve,
I=current density (mA/cm ² )

(4) Water flow test At the point 5 cm in height from the electrode, a drop of ion-exchanged water was dropped onto the electrode from a 3 mmφ pipette, and the time taken for the water drops to permeate was measured. The water flow rate was calculated by.
Water flow rate (mm/sec)
= Thickness of electrode material (mm) / Time until water droplets penetrate (sec)

[About the first electrode material]
Example 1
In this example, as the carbonaceous material (B), pitches of MCP250 manufactured by JFE Chemical Co., Ltd. or phenolic resin of TD-4304 manufactured by DIC Corporation (solid content 40%) was used, and an electrode material was prepared as follows. Then, various items were measured.

(No. 1)
<Preparation of nonwoven fabric A made of carbonaceous fibers>
Polyacrylonitrile fiber having an average fiber diameter of 16 μm is heated at 300° C. in an air atmosphere to be flame resistant, and a felt needle SB#40 (Foster Needle Co., Ltd.) using a short fiber (length 80 mm) of the flame resistant fiber, punching density Nonwoven fabric A (felt made of flame-resistant polyacrylonitrile fiber) having a basis weight of 300 g/m ² and a thickness of 4.3 mm was prepared by making the felt into 250 felts/cm ² .

<Impregnation of carbonaceous material (binder)>
Ion-exchanged water: 83.0%, polyvinyl alcohol: 1.0%, Kao Corporation's Rheodor TW-L120 2.0%, and JFE Chemical's MCP250 pitches: 14.0% as carbonaceous material. The mixture was stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid.

After the above-mentioned nonwoven fabric A is dipped in the prepared dispersion liquid, the excess dispersion liquid is passed through a nip roller so that the weight of the nonwoven fabric after immersion is 1.9 to 2.1 times that of the nonwoven fabric A before immersion. Was removed and dried at 150° C. for 20 minutes.

<Carbonization of non-woven fabric>
Next, the non-woven fabric A after the above treatment is heated to 1000° C.±50° C. at a heating rate of 5° C./min in nitrogen gas, and held at this temperature for 1 hour for carbonization (calcination). After cooling, the temperature was raised to 1500° C.±50° C. at a heating rate of 5° C./min in nitrogen gas, and the temperature was maintained for 1 hour to graphitize and cool. Next, in an air atmosphere, oxidation treatment was performed at 700° C. for 10 minutes, and No. An electrode material of No. 1 (Basis weight 191 g/m ² , thickness 3.4 mm) was obtained.

(No. 2)
No. In No. 1, the excess dispersion liquid was removed by passing it through a nip roller so that the weight of the nonwoven fabric after immersion was 1.6 to 1.8 times that of the nonwoven fabric A before immersion, and the amount of carbonaceous material impregnated was changed. Other than the above, the above No. The same process as No. 1 is performed, and No. Two electrode materials (basis weight 174 g/m ² , thickness 3.2 mm) were obtained.

(No. 3)
No. 1, instead of the felt made of flame-resistant polyacrylonitrile fiber as the carbonaceous fiber, carbon paper made of polyacrylonitrile fiber (average fiber diameter 10 μm) (CFP-030-PE manufactured by Nippon Polymer Sangyo Co., Ltd., basis weight 30 g/m ^{2 ).} , Thickness 0.51 mm). No. 1 except that drying, carbonization (calcination), graphitization, and oxidation treatment were performed as in No. 1. Similar to No. 1, 3 (thickness 0.57 mm, basis weight 64 g/m ² ) was prepared.

(No. 4)
No. In place of the felt made of flame-resistant polyacrylonitrile fiber as the carbonaceous fiber, spunlace made of polyacrylonitrile fiber (average fiber diameter 10 μm) (basis weight 100-120 g/m ² , thickness 0.9 mm) was used as nitrogen gas. In the carbonized spun lace (weight per unit area: 50 to 60 g/m ² , thickness: 0), the temperature was raised to 1000° C.±50° C. at a temperature rising rate of 5° C./min, and the temperature was maintained for 1 hour. No. 5 to 0.7 mm) was used. Similar to No. 1, 4 (thickness 0.65 mm, basis weight 105 g/m ² ) was prepared.

(No. 5)
No. In No. 1, the excess amount of the dispersion liquid is removed by passing through a nip roller so that the weight of the nonwoven fabric after immersion is 1.3 to 1.5 times that of the nonwoven fabric A before immersion, and the amount of carbonaceous material added is changed. Other than the above, the above No. The same process as No. 1 is performed, and No. 5 electrode material (Basis weight 159 g/m ² , thickness 3.2 mm) was obtained.

(No. 6)
The above No. No. 1 was added to the non-woven fabric A described in 1 without adding a carbonaceous material (binder). <Carbonization of non-woven fabric> is performed in the same manner as in No. Electrode material No. 6 (Basis weight 143 g/m ² , thickness 3.4 mm) was obtained.

(No. 7)
No. 1, the ion-exchanged water: 64.0%, polyvinyl alcohol: 1.0%, TD-4304 made by DIC Co., Ltd. as a carbonaceous material, phenol resin (solid content 40%): 35.0%, using a mechanical stirrer. The above No. 1 was used except that the dispersion liquid obtained by stirring for 1 hour was used. The same process as No. 1 is performed, and No. Electrode material No. 7 (Basis weight: 188 g/m ² , thickness: 3.4 mm) was obtained.

(No. 8)
The above No. No. 1 <carbonization of non-woven fabric> except that the oxidation treatment was not performed at 700° C. in an air atmosphere. Similar to No. 1, No. 8 electrode material (Basis weight 189 g/m ² , thickness 3.3 mm) was obtained.

(No. 9)
The above No. In <Carbonization of non-woven fabric> of No. 1, No. 1 except that the graphitization temperature was changed to 2000° C.±50° C. Similar to No. 1, Nine electrode materials (Basis weight 191 g/m ² , thickness 3.4 mm) were obtained.

Thus obtained No. Various items were measured for the electrode materials 1 to 9, and the results are also shown in Table 1.

No. 1 to 4 are electrode materials that satisfy the requirements for the first electrode material, and low resistance was realized.
On the other hand, No. No. 5 is an example in which the content of the carbonaceous material is small, and because the binding between the carbonaceous fibers is insufficient and an efficient conductive path cannot be formed, it is considered that the resistance is increased.

No. No. 6 is an example in which no carbonaceous material is used and only carbonaceous fiber is used. The resistance was increased as compared with Examples 1 to 4 of the present invention.

No. No. 7 is an example in which the ratio of Lc(B)/Lc(A) is small, and the resistance is increased. It is considered that this is because the carbon crystallinity of the carbonaceous material was lower than that of the examples of the present invention, so that the electron conduction resistance between the carbonaceous fibers was high and an efficient conductive path could not be formed.

No. No. 8 is an example in which O/C was low, resistance increased, and water did not pass. It is considered that this is because the oxygen functional group was small and the affinity with the electrolytic solution was decreased and the reaction activity was decreased as compared with the examples of the present invention.

No. No. 9 is an example in which the graphitization temperature was increased to 2000° C. and Lc(B) was increased to 12.0 nm. It is considered that since Lc(B) was excessively high, the affinity with the electrolytic solution was lowered and the resistance was increased.

[About the second electrode material]
Example 2
In the present example, the scale-like graphite particles A to D shown in Table 2 were used to prepare an electrode material as described below, and various items were measured. Of these, A, B, and D are commercial products, and the particle diameters shown in Table 1 are the values shown in the catalog. C is a scaly graphite particle having a particle size of 5 μm, which was crushed by a bead mill for 6 hours using a Labstar mini machine manufactured by Ashizawa Finetech Co., Ltd. The particle size was measured by a laser diffraction method. Note that D is an example in which Lc is large.

(No. 1)
No. In No. 1, polyacrylonitrile fiber was used as the carbonaceous fiber, A of Table 1 was used as the graphite particles (an example satisfying the requirements for the second electrode material), and pitches of MCP250 manufactured by JFE Chemical Co. were used as the carbonaceous material. Then, an electrode material was produced.

First, polyacrylonitrile fiber (average fiber diameter 10 μm) is heated at 300° C. in an air atmosphere to be flame-resistant, and a felt needle SB#40 (Foster Needle Company) is used by using the flame-resistant fiber short fiber (length 80 mm). After obtaining a felt made of flame-resistant polyacrylonitrile fiber by punching with a punching density of 250 wires/cm ² (thickness: 4.3 mm, basis weight: 150 g/m ² ), subsequently, firing at 1000° C. for 1 hour in a nitrogen atmosphere ( Carbonized). The temperature rising rate when the temperature was raised from the flameproofing temperature to the carbonization temperature was 10° C./min or less.

Next, in ion-exchanged water, 1.8% of Leodol TW-L120 (nonionic surfactant) manufactured by Kao, 1.8% of polyvinyl alcohol (temporary adhesive), MCP250 (carbonaceous material manufactured by JFE Chemical Co., Ltd.) Material) was added in an amount of 14% and graphite powder A in Table 1 was added so as to be 9.8%, and the mixture was stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid.

The felt thus calcined at 1000° C. was immersed in the dispersion liquid thus obtained, and then passed through a nip roller to remove an excess dispersion liquid. Next, after drying at 150° C. for 20 minutes in an air atmosphere, carbonization (calcination) was performed at 1000° C. for 1 hour in a nitrogen atmosphere, and then graphitization was further performed at 1500° C. for 1 hour. After graphitization, oxidation treatment was performed at 700° C. for 10 minutes in an air atmosphere to obtain an electrode material (No. 1) having a thickness of 3.8 mm and a basis weight of 278.0 g/m ² .

(No. 2)
No. In Example 1, B of Table 1 (an example satisfying the requirements for the second electrode material) was used as the graphite powder; inclusion of graphite particles and carbonaceous material in the total amount of carbonaceous fiber, graphite particles, and carbonaceous material. The above No. except that the rate was changed as shown in Table 2. Similar to No. 1, 2 (thickness 3.9 mm, basis weight 301.0 g/m ² ) was prepared.

(No. 3)
No. 1. In Example 1, C of Table 1 (an example satisfying the requirements of the second electrode material) was used as the graphite powder; inclusion of the graphite particles and the carbonaceous material with respect to the total amount of carbonaceous fiber, graphite particles, and carbonaceous material. The above No. except that the rate was changed as shown in Table 2. Similar to No. 1, 3 (thickness 4.0 mm, basis weight 294.0 g/m ² ) of an electrode material was produced.

(No. 4)
No. In 1, the carbonaceous fiber, instead of the felt made of flame-resistant polyacrylonitrile fiber, carbon paper made of polyacrylonitrile fiber (average fiber diameter 10 μm) (CFP-030-PE manufactured by Nippon Polymer Sangyo Co., Ltd., basis weight 30 g/m ^{2 ).} , Thickness 0.51 mm). Drying, carbonization (calcination), graphitization, and oxidation treatment were carried out in the same manner as in 1; the content ratio of the graphite particles and the carbonaceous material to the total amount of the carbonaceous fiber, the graphite particles, and the carbonaceous material is shown in Table 2. No. except changed to Similar to No. 1, 4 (thickness 0.57 mm, basis weight 137.0 g/m ² ) was prepared.

(No. 5)
No. 1, in place of the felt made of flame-resistant polyacrylonitrile fiber, spunlace made of polyacrylonitrile fiber (average fiber diameter 10 μm) (unit weight: 100 to 120 g/m ² , thickness: 0.9 mm) was used as a carbonaceous fiber in nitrogen gas. In the carbonized spunlace (weight per unit area: 50 to 60 g/m ² , thickness: 0.50° C./minute), the temperature was raised to 1000° C.±50° C. at a heating rate of 5° C./min, and the temperature was maintained for 1 hour. No. 5 to 0.7 mm), except that graphite powder (A in Table 1) was added to 4.9% to obtain a dispersion liquid. Similar to No. 1, 5 (thickness 0.65 mm, basis weight 189.0 g/m ² ) was prepared.

(No. 6)
No. In Table 1, D of Table 1 (example not satisfying the requirements for the second electrode material) was used as the graphite powder in Example 1; inclusion of the graphite particles and the carbonaceous material in the total amount of the carbonaceous fiber, the graphite particles, and the carbonaceous material. The above No. except that the rate was changed as shown in Table 2. Similar to No. 1, A 6 (thickness 3.7 mm, basis weight 278.0 g/m ² ) electrode material (comparative example) was produced.

(No. 7)
No. In No. 7, No. 7 No. 1 except that the graphite particles and the carbonaceous material were not used, and the felt (thickness 4.3 mm, basis weight 300 g/m ² ) made of flame-resistant polyacrylonitrile fiber was used as the carbonaceous fiber. The same process as No. 1 is performed. 7 (thickness: 4.3 mm, basis weight: 150.0 g/m ² ) was prepared as an electrode material (comparative example).

(No. 8)
No. No. 1 except that carbonization (calcination) was performed at 1000° C. for 1 hour in a nitrogen atmosphere, graphitization was further performed at 2000° C. for 1 hour, and oxidation treatment was performed at 700° C. for 20 minutes in an air atmosphere. Similar to No. 1, 8 (thickness 3.8 mm, basis weight 278.0 g/m ² ) of an electrode material (comparative example) was produced.

(No. 9)
No. No. 1 except that 3 mass% of MCP250 (carbonaceous material) manufactured by JFE Chemical Co., Ltd. and 2.1 mass% of A in Table 1 were added as graphite powder. Similar to No. 1, 9 (thickness 0.56 mm, basis weight 194.0 g/m ² ) was prepared as an electrode material (comparative example).

(No. 10)
No. No. 8, except that no oxidation treatment was performed at 700° C. in an air atmosphere. Similar to No. 8, 10 (thickness 3.8 mm, basis weight 290.0 g/m ² ) of an electrode material (comparative example) was produced.

(No. 11)
No. In 1, the carbonaceous material was obtained by adding 10% by mass of a phenol resin aqueous dispersion (TD4304 manufactured by DIC Co., Ltd.) as a carbonaceous material instead of MCP250 manufactured by JFE Chemical Co.; carbonaceous fiber, graphite particles, No. 1 except that the content ratio of the graphite particles and the carbonaceous material with respect to the total amount of the carbonaceous material was changed as shown in Table 2. Similar to No. 1, 11 (thickness 3.8 mm, basis weight 288.0 g/m ² ) of an electrode material (comparative example) was produced.

In Table 3, the above No. The measurement results of various items in 1 to 11 are shown.

No. 1 to 5 are electrode materials that satisfy the requirements for the second electrode material, and all of them have low resistance.

On the other hand, No. No. 6 is an example of using graphite D in which Lc does not satisfy the requirement of the second electrode material, and the resistance was increased because the reactivity of the graphite particles was poor.

No. No. 7 is an example made of only carbonaceous fiber without using graphite particles or carbonaceous material, and the resistance increased.

No. No. 8 is an example in which the graphitization temperature was increased to 2000° C. and Lc(C) was increased to 12.0 nm. Since Lc(C) was excessively high, the affinity with the electrolytic solution was lowered and the resistance was increased. It is considered that the utilization rate of graphite deteriorated.

No. In No. 9, graphite particles and a carbonaceous material satisfying the requirements for the second electrode material were used, but the resistance was increased as compared with the examples of the present invention because their contents were small. It is considered that the content of graphite was small and the effective surface area was insufficient.

No. No. 10 is an example in which the O/C ratio is low because the oxidation treatment after graphitization was not performed. Since the amount of functional groups on the carbon surface was insufficient, the affinity with the electrolytic solution decreased and the resistance increased. It is considered that the utilization rate of graphite deteriorated.

No. In No. 11, graphite particles satisfying the requirements for the second electrode material were used, but Lc(C) was not sufficiently large, and the ratio of Lc(C)/Lc(A) was as small as 1.0 or less. is there. Therefore, the resistance increased as compared with the example of the present invention. Although the affinity of the electrolytic solution is high, it is considered that the conductivity of the carbonaceous material (C) is insufficient.

[About the third electrode material]
Example 3
In this example, as carbon particles (B) other than graphite, carbon blacks of A to E shown in Table 4, graphite particles of F, and a shown in Table 5 as carbonaceous material (C) (of MCP250 manufactured by JFE Chemical Corporation) Pitches), b (phenolic resin of TD-4304 manufactured by DIC Corporation, solid content 40%) or c (coal tar manufactured by Alfa Aesar) is used to prepare an electrode material composed of a carbonaceous sheet as follows. Various items were measured. All of A to F are commercial products, and the average particle size shown in Table 1 is the value described in the catalog.

(No. 1)
Ion-exchanged water: 19.2%, polyvinyl alcohol: 1.0%, A of Table 1 as carbon particles other than graphite particles (solid content: 16.5%, carbon content other than graphite particles: about 8.5%) , Example satisfying the requirements of the third electrode material): 65.8%, a: 14.0% of carbonaceous material in Table 5 (residual carbonization weight yield 80%) is stirred with a mechanical stirrer for 1 hour. , A dispersion liquid.

Next, a polyacrylonitrile fiber having an average fiber diameter of 16 μm is heated at 300° C. in an air atmosphere to be flame-resistant, and a felt needle SB#40 (Foster Needle Company) is used by using the short fiber (length 80 mm) of the flame-resistant fiber. A nonwoven fabric A having a basis weight of 300 g/m ² and a thickness of 4.3 mm was prepared by forming a felt with a punching density of 250 fibers/cm ² .

After the above-mentioned nonwoven fabric A is dipped in the prepared dispersion liquid, it is passed through a nip roller so that the weight of the nonwoven fabric A after immersion is 2.1 to 2.3 times the weight of the nonwoven fabric A before immersion. The excess dispersion liquid was removed by drying, and it was dried at 150° C. for 20 minutes in an air atmosphere. Next, in nitrogen gas, the temperature is raised to 1000° C.±50° C. at a heating rate of 5° C./min, and the temperature is maintained for 1 hour for carbonization (calcination), followed by cooling and further in nitrogen gas. The temperature was raised to 1500° C.±50° C. at a heating rate of 5° C./min, and the temperature was maintained for 1 hour for graphitization and cooling. Next, in an air atmosphere, oxidation treatment was performed at 700° C. for 10 minutes, and No. Thus, an electrode material No. 1 (basis weight 206 g/m ² , thickness 3.3 mm) was obtained.

(No. 2)
Ion-exchanged water: 50.9%, polyvinyl alcohol (temporary adhesive): 1.0%, A: 34.1% in Table 1 as carbon particles other than graphite particles, and a: 14. 0% was stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

In the prepared dispersion liquid, No. After immersing the non-woven fabric A in No. 1, the non-woven fabric A before dipping is passed through a nip roller so that the weight of the non-woven fabric A after immersing is 2.3 to 2.5 times, and excess dispersion liquid is removed. No. above except that the amount of carbonaceous material impregnated was changed. The same process as No. 1 is performed, and No. Two electrode materials (Basis weight: 208 g/m ² , thickness: 3.2 mm) were obtained.

(No. 3)
Ion-exchanged water: 68.1%, polyvinyl alcohol: 1.0%, carbon particles other than graphite particles: A: 16.9% in Table 1; carbonaceous material: a: 14.0% in Table 5 The mixture was stirred with a stirrer for 1 hour to give a dispersion.

In the prepared dispersion liquid, No. After immersing the non-woven fabric A in No. 1, pass through a nip roller so that the weight of the non-woven fabric A before immersing becomes 2.5 to 2.7 times, and remove the excess dispersion liquid. No. above except that the amount of carbonaceous material impregnated was changed. The same process as No. 1 is performed, and No. Electrode material No. 3 (Basis weight 213 g/m ² , thickness 3.3 mm) was obtained.

(No. 4)
No. No. 2 in the dispersion liquid prepared in 2. After immersing carbon paper (CFP-030-PE manufactured by Nippon Polymer Sangyo Co., Ltd., basis weight 30 g/m ² , thickness 0.51 mm) made of polyacrylonitrile fiber (average fiber diameter 10 μm) instead of the nonwoven fabric A in 1 before immersion No. except that the amount of carbonaceous material impregnated was changed by passing through a nip roller to remove excess dispersion liquid so that the weight of the carbon paper after immersion was 14 to 15 times that of the carbon paper ． The same process as No. 1 is performed, and No. No. 4 electrode material (Basis weight 119 g/m ² , thickness 0.45 mm) was obtained.

(No. 5)
No. No. 2 in the dispersion liquid prepared in 2. In place of the non-woven fabric A in No. 1, spunlace (weight per unit area: 100 to 120 g/m ² , thickness: 0.9 mm) made of polyacrylonitrile fiber (average fiber diameter: 10 μm) was 1000 in nitrogen gas at a heating rate of 5° C./min. After immersing the carbonized spunlace (Basis weight 50-60 g/m ² , thickness 0.5-0.7 mm) which has been carbonized by raising the temperature to ±50°C and holding for 1 hour after the temperature rise, Other than changing the impregnated amount of the carbonaceous material by passing it through a nip roller so that the weight after immersion is 4.4 to 4.6 times that of the carbonized sparence before immersion. Is the above No. The same process as No. 1 is performed, and No. 5 electrode material (Basis weight 119 g/m ² , thickness 0.62 mm) was obtained.

(No. 6)
Ion-exchanged water: 36.3%, polyvinyl alcohol: 1.0%, as carbon particles other than graphite particles, B in Table 1 (solid content 11.5%, carbon content other than graphite particles is about 3.5%. , An example satisfying the requirements for the third electrode material): 48.7%, and a: 14.0% in Table 5 as a carbonaceous material were stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

In the prepared dispersion liquid, No. After immersing the non-woven fabric A in No. 1, pass through a nip roller so that the weight of the non-woven fabric A before immersing becomes 2.5 to 2.7 times, and remove the excess dispersion liquid. No. above except that the amount of carbonaceous material impregnated was changed. The same process as No. 1 is performed, and No. Electrode material No. 6 (weight per unit area 209 g/m ² , thickness 3.3 mm) was obtained.

(No. 7)
Ion-exchanged water: 77.4%, polyvinyl alcohol: 1.0%, Kao Corporation's Leodol TW-L120 2.0%, C as shown in Table 4 as carbon particles other than graphite particles (requirements for the third electrode material). Satisfying the requirement): 5.6%, and a: 14.0% in Table 5 as a carbonaceous material were stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

No. 3 except that the dispersion liquid prepared above was used. The same process as No. 1 is performed, and No. The electrode material of No. 7 (Basis weight 217 g/m ² , thickness 3.5 mm) was obtained.

(No. 8)
Ion-exchanged water: 77.4%, polyvinyl alcohol: 1.0%, Kao Corporation's Rheodor TW-L120 2.0%, as carbon particles other than graphite particles D in Table 4 (Requirements for third electrode material) Satisfying the requirement): 5.6%, and a: 14.0% in Table 5 as a carbonaceous material were stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

No. 3 except that the dispersion liquid prepared above was used. The same process as No. 1 is performed, and No. No. 8 electrode material (basis weight: 211 g/m ² , thickness: 3.3 mm) was obtained.

(No. 9)
Ion-exchanged water: 77.4%, polyvinyl alcohol: 1.0%, Kao Corporation's Rheodor TW-L120 2.0%, as carbon particles other than graphite particles E in Table 4 (Requirements for the third electrode material) Satisfying the requirement): 5.6%, and a: 14.0% in Table 5 as a carbonaceous material were stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

No. 3 except that the dispersion liquid prepared above was used. The same process as No. 1 is performed, and No. Electrode material No. 9 (weight per unit area 210 g/m ² , thickness 3.3 mm) was obtained.

(No. 10)
No. No. 10 is an example made of only carbonaceous fibers without using carbon particles other than graphite particles or carbonaceous material. In detail, directly with respect to the nonwoven fabric A, No. The same heat treatment as in No. 1 was performed, and No. Ten electrode materials (Basis weight 143 g/m ² , thickness 3.4 mm) were obtained.

(No. 11)
No. No. 11 is an example made of only carbonaceous fiber and carbonaceous material without using carbon particles other than graphite particles.
First, ion-exchanged water: 83.0%, polyvinyl alcohol: 1.0%, Kao Corporation's Leodol TW-L120 2.0%, and a: 14.0% of Table 2 as a carbonaceous material with a mechanical stirrer. The mixture was stirred for 1 hour to give a dispersion.

No. 3 except that the dispersion liquid prepared above was used. The same process as No. 1 is performed, and No. Eleven electrode materials (basis weight 191 g/m ² , thickness 3.4 mm) were obtained.

(No. 12)
Ion-exchanged water: 77.4%, polyvinyl alcohol: 1.0%, Kao Corporation's Rheodor TW-L120 2.0%, graphite particles F in Table 4 (examples not satisfying the requirements): 5.6% As a carbonaceous material, a: 14.0% in Table 5 was stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid.

No. 3 except that the dispersion liquid prepared above was used. The same process as No. 1 is performed, and No. Twelve electrode materials (weight per unit area 209 g/m ² , thickness 3.4 mm) were obtained.

(No. 13)
Ion-exchanged water: 8.9%, polyvinyl alcohol: 1.0%, A of carbon particles other than graphite particles in Table 1 (solid content 16.5%, carbon content other than graphite particles was about 8.5%). , Which satisfies the requirement of the third electrode material): 34.1%, b (solid content 40%) of Table 2 as a carbonaceous material: 56.0% is stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid. And

In the prepared dispersion liquid, No. After immersing the nonwoven fabric A in No. 1, No. 1 The same process as in No. 2 is performed and No. Thirteen electrode materials (area weight: 208 g/m ² , thickness: 3.4 mm) were obtained.

(No. 14)
No. No. 2 in the dispersion liquid prepared in 2. After immersing the nonwoven fabric A in No. 1, No. 1 Carbonization and graphitization were performed in the same manner as in No. 2, but the subsequent oxidation treatment in an air atmosphere was not performed. 14 electrode materials (basis weight: 211 g/m ² , thickness: 3.2 mm) were obtained.

(No. 15)
No. No. 2 in the dispersion liquid prepared in 2. After dipping the non-woven fabric A in No. 1, except that the excess dispersion was removed by passing it through a nip roller so that the weight of the non-woven fabric after dipping was 1.5 to 1.7 times that of the non-woven fabric A before dipping. No. The same process as No. 1 is performed, and No. Fifteen electrode materials (Basis weight 175 g/m ² , thickness 3.3 mm) were obtained.

(No. 16)
Ion-exchanged water: 10.0%, polyvinyl alcohol: 1.0%, A of Table 4 as carbon particles other than graphite particles (solid content 16.5%, carbon content other than graphite particles is about 8.5%) , Example satisfying the requirement of the third electrode material): 98.0%, a: 1.0% of carbonaceous material shown in Table 5 was stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid.

In the prepared dispersion liquid, No. After dipping the non-woven fabric A in No. 1, except that the excess dispersion liquid was removed by passing it through a nip roller so that the weight of the non-woven fabric after dipping was 3.0 to 3.2 times that of the non-woven fabric A before dipping. No. The same process as No. 1 is performed, and No. 16 electrode materials (basis weight 205 g/m ² , thickness 3.3 mm) were obtained.

(No. 17)
Ion-exchanged water: 71.8%, polyvinyl alcohol: 1.0%, as carbon particles other than graphite particles, A in Table 4 (solid content 16.5%, carbon content other than graphite particles is about 8.5%, An example satisfying the requirements of the third electrode material): 13.2%, and a: 14.0% of carbonaceous material shown in Table 5 were stirred for 1 hour with a mechanical stirrer to obtain a dispersion liquid.

In the prepared dispersion liquid, No. After dipping the nonwoven fabric A in No. 1, except that the excess dispersion was removed by passing through a nip roller so that the weight of the unwoven fabric after dipping was 2.3 to 2.5 times that of the unwoven fabric A before dipping. No. The same process as No. 1 is performed, and No. 17 electrode materials (basis weight: 211 g/m ² , thickness: 3.3 mm) were obtained.

(No. 18)
As carbon particles other than graphite particles, C in Table 4 (an example satisfying the requirements of the third electrode material): 4.8%, and as a carbonaceous material, c in Table 5 (residual carbonization weight yield 10%): 95. 2% was stirred with a mechanical stirrer for 1 hour to obtain a dispersion liquid.

In the prepared dispersion liquid, No. After the non-woven fabric A in No. 1 was immersed, the excess dispersion was removed by passing through a nip roller so that the weight of the non-woven fabric before immersing was 1.9 to 2.1 times, and graphitization was performed. No. except that the temperature was changed to 2000°C ± 50°C. The same process as No. 1 is performed, and No. Eighteen electrode materials (basis weight 195 g/m ² , thickness 3.2 mm) were obtained.

In Table 6, the above No. The measurement results of various items in 1 to 18 are shown.

No. Nos. 1 to 9 are electrode materials that satisfy the requirements for the third electrode material, and all of them are No. Electrode materials having a lower resistance than those of Comparative Examples 10 to 18 were obtained. No. In Examples 1 to 9 of the present invention, since A to E of Table 4 having a small particle size were used as the carbon particles other than graphite, it is considered that the reaction surface area was large and the electrode activity was improved by the exposure of the carbon edge surface.

On the other hand, No. No. 10 is an example made of only carbonaceous fibers without using carbon particles other than graphite particles or carbonaceous material, and the resistance was remarkably increased because the reaction surface area was insufficient. No. Since No. 11 did not contain carbon particles other than graphite particles, the reaction surface area was insufficient and the resistance significantly increased.

No. In No. 12, carbon particles other than graphite particles having a large particle size and having a large Lc(B) were used as F in Table 1, so that the resistance increased. The reaction surface area becomes smaller when using large-diameter carbon particles as compared with the present invention example, and since it is difficult to impart an oxygen functional group when using carbon particles having high carbon crystallinity, it becomes It is considered that the affinity decreased and the reaction activity did not improve.

No. No. 13 is an example in which the ratio of Lc(C)/Lc(A) is small, and the resistance is increased. This is because the carbon crystallinity of the carbonaceous material is lower than that of the example of the present invention, so that the electron conduction resistance between the carbon particles and the carbonaceous fiber becomes high, and the reaction activity of the carbon particles could not be efficiently utilized. To be

No. No. 14 was an example in which the O/C ratio was small, the resistance increased, and water did not pass. It is considered that this is because the amount of oxygen functional groups was small, so that the affinity with the electrolytic solution was decreased and the reaction activity was decreased as compared with the examples of the present invention.

No. No. 15 is an example in which the content of carbon particles other than graphite was small, and the resistance increased. It is considered that when the content of the carbon particles is small, the reaction surface area is reduced, and the electron conduction path becomes insufficient as the content is reduced.

No. No. 16 is an example in which the content of carbon particles other than graphite is small and the ratio of the carbonaceous material to the carbon particles is small, and the resistance increased. It is speculated that this is because the ratio of carbon particles other than graphite is remarkably higher than that of the carbonaceous material, so that the binding property is insufficient and the particles are dropped from the carbonaceous fiber to increase the resistance.
In addition, No. No. 17 is an example in which the ratio of the carbonaceous material to the carbon particles other than graphite is large, and the resistance also increased. This is because the ratio of the carbonaceous material is significantly higher than that of carbon particles other than graphite, so that the carbonaceous material covers the reaction active points on the surface of the carbon particles, and the reaction surface area is not effectively used and the resistance increases. Inferred.
No. In No. 18, the Lc(C)/Lc(A) ratio was 7.2, which is an example in which the carbon crystallinity of the carbonaceous material is significantly higher than that of the carbonaceous fiber, and the resistance also increased. When carbon particles other than graphite are coated on a very highly crystalline carbonaceous material, the reaction surface area of the carbon particles is not effectively used, and in general, it is difficult to introduce oxygen functional groups into highly crystalline sites. It is surmised that the affinity with the electrolytic solution decreased and the resistance increased.

According to the first and second carbon electrode materials, the cell resistance at the time of initial charge/discharge can be reduced, and a carbon electrode material excellent in battery energy efficiency can be provided. Therefore, for example, in a redox flow battery using a vanadium-based electrolyte solution. It is useful as an electrode material.
In addition, according to the third carbon electrode material, the cell resistance at the time of initial charge/discharge can be reduced, and a carbon electrode material having excellent battery energy efficiency can be provided. Therefore, for example, a vanadium-based electrolyte solution, a Mn/Ti-based electrolyte solution, etc. It is useful as an electrode material for a redox flow battery using a.
The first to third carbon electrode materials are suitably used for flow type and non-flow type redox flow batteries, and redox flow batteries combined with lithium, capacitor, and fuel cell systems.

1 Current Collector Plate 2 Spacer 3 Ion Exchange Membrane 4a, 4b Liquid Flow Path 5 Electrode Material 6 Positive Electrolyte Tank 7 Negative Electrolyte Tank 8, 9 Pump 10 Liquid Inlet 11 Liquid Outlet 12, 13 External Channel

Claims (15)

A carbonaceous fiber (A) and a carbonaceous material (B) binding the carbonaceous fiber (A),
A carbon electrode material for redox flow batteries, which satisfies the following requirements.
(1) In the carbonaceous material (B), when the crystallite size in the c-axis direction obtained by X-ray diffraction is Lc(B), Lc(B) is less than 10 nm,
(2) When the crystallite size in the c-axis direction in the carbonaceous fiber (A) determined by X-ray diffraction is Lc(A), Lc(B)/Lc(A) is 1.0 or more,
(3) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. The carbon electrode material according to claim 1, wherein a mass content rate of the carbonaceous material (B) with respect to a total amount of the carbonaceous fiber (A) and the carbonaceous material (B) is 14.5% or more. The carbon electrode material according to claim 1 or 2, wherein the Lc(A) is 1 to 10 nm. A method for producing the carbon electrode material according to claim 1,
Attaching the carbonaceous material (B) before carbonization to the carbonaceous fiber (A),
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order. A carbonaceous fiber (A), graphite particles (B), and a carbonaceous material (C) binding these,
A carbon electrode material for redox flow batteries, which satisfies the following requirements.
(1) When the size of the crystallite in the c-axis direction in the graphite particles (B) determined by X-ray diffraction is Lc(B), Lc(B) is less than 35 nm,
(2) When the size of the crystallite in the c-axis direction in the carbonaceous material (C) determined by X-ray diffraction is Lc(C), Lc(C) is less than 10 nm,
(3) When the crystallite size in the c-axis direction in the carbonaceous fiber (A) obtained by X-ray diffraction is Lc(A), Lc(C)/Lc(A) is 1.0 or more,
(4) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. The mass content of the carbonaceous material (C) with respect to the total amount of the carbonaceous fibers (A), the graphite particles (B), and the carbonaceous material (C) is 14.5% or more, and The carbon electrode material according to claim 5, wherein the mass ratio of the carbonaceous material (C) to the graphite particles (B) is 0.2 to 3.0. The carbon electrode material according to claim 5 or 6, wherein the BET specific surface area determined from the amount of adsorbed nitrogen is more than 8 m ² /g. A method for producing the carbon electrode material according to any one of claims 5 to 7, comprising:
Attaching the graphite particles (B) and the carbonaceous material before carbonization (C) to the carbonaceous fibers (A);
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order. A carbonaceous fiber (A), carbon particles (B) other than graphite particles, and a carbonaceous material (C) binding these,
A carbon electrode material for redox flow batteries, which satisfies the following requirements.
(1) The particle size of the carbon particles (B) other than the graphite particles is 1 μm or less,
(2) In the carbon particles (B) other than the graphite particles, when the crystallite size in the c-axis direction obtained by X-ray diffraction is Lc(B), Lc(B) is 10 nm or less,
(3) When the crystallite sizes in the c-axis direction in the carbonaceous fiber (A) and the carbonaceous material (C) obtained by X-ray diffraction are Lc(A) and Lc(C), respectively, Lc( C)/Lc(A) is 1.0 to 5,
(4) The mass content of the carbonaceous material (C) is 14.5% or more based on the total amount of the carbonaceous fiber (A), the carbon particles (B) other than the graphite particles, and the carbonaceous material (C).
(5) The number of bonded oxygen atoms on the surface of the carbon electrode material is 1% or more of the total number of carbon atoms on the surface of the carbon electrode material. The carbon electrode material according to claim 9, wherein a mass ratio of the carbonaceous material (C) to the carbon particles (B) is 0.2 to 10. The carbon electrode material according to claim 9 or 10, which has a BET specific surface area of 0.5 m ² /g or more, which is determined from the amount of adsorbed nitrogen. A method for producing the carbon electrode material according to any one of claims 9 to 11, comprising:
Attaching carbon particles (B) other than the graphite particles and carbonaceous material (C) before carbonization to the carbonaceous fibers (A);
A carbonization step of heating the product after impregnation at a temperature of 800° C. or higher and 2000° C. or lower in an inert atmosphere,
A graphitization step of heating at a temperature of 1300° C. or higher in an inert atmosphere and at a temperature higher than the heating temperature of the carbonization step;
A method of manufacturing a carbon electrode material, which comprises an oxidation treatment step in this order. The carbon electrode material according to any one of claims 1 to 3, 5 to 7, and 9 to 11, which has a water passage rate of 0.5 mm/sec or more when water drops are dropped. A redox flow battery comprising the carbon electrode material according to any one of claims 1 to 3, 5 to 7, 9 to 11, and 13. A vanadium redox flow battery using the carbon electrode material according to any one of claims 1 to 3, 5 to 7, and 13.

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