WO2015005370A1 - 電解質膜、膜-電極接合体および固体高分子型燃料電池 - Google Patents
電解質膜、膜-電極接合体および固体高分子型燃料電池 Download PDFInfo
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- WO2015005370A1 WO2015005370A1 PCT/JP2014/068267 JP2014068267W WO2015005370A1 WO 2015005370 A1 WO2015005370 A1 WO 2015005370A1 JP 2014068267 W JP2014068267 W JP 2014068267W WO 2015005370 A1 WO2015005370 A1 WO 2015005370A1
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- H01M8/103—Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having nitrogen, e.g. sulfonated polybenzimidazoles [S-PBI], polybenzimidazoles with phosphoric acid, sulfonated polyamides [S-PA] or sulfonated polyphosphazenes [S-PPh]
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Definitions
- the present invention relates to an electrolyte membrane, a membrane-electrode assembly, and a polymer electrolyte fuel cell.
- a fuel cell is a power generator that directly takes out electricity by electrochemically reacting hydrogen gas obtained by reforming various hydrocarbon fuels (natural gas, methane, etc.) and oxygen gas in the air. It is attracting attention as a pollution-free power generator that can directly convert chemical energy into electrical energy with high efficiency.
- Such a fuel cell has a membrane-electrode junction comprising a pair of electrode catalyst layers (anode electrode and cathode electrode) carrying a catalyst and a proton conductive solid polymer electrolyte membrane sandwiched between the electrode catalyst layers.
- anode electrode hydrogen ions and electrons are generated, and the hydrogen ions pass through the solid polymer electrolyte membrane and react with oxygen at the cathode electrode to generate water.
- Patent Document 1 discloses, as the solid polymer electrolyte membrane, a block copolymer of a hydrophilic segment and a hydrophobic segment represented by the following formula, and an electrolyte comprising an aromatic polymer comprising the hydrophobic segment. A membrane is disclosed. Note that only this electrolyte membrane is specifically described in Patent Document 1.
- the membrane-electrode assembly may be produced by previously providing an electrode catalyst layer on a substrate such as polyethylene terephthalate (PET) and thermally transferring the electrode catalyst layer to a solid polymer electrolyte membrane.
- a substrate such as polyethylene terephthalate (PET)
- PET polyethylene terephthalate
- the solid polymer electrolyte membrane described in Patent Document 1 When a membrane-electrode assembly is produced by such a method, and the electrolyte membrane described in Patent Document 1 is used as the solid polymer electrolyte membrane, the solid polymer electrolyte membrane must be used unless thermal transfer is performed at a high temperature. Even if a membrane-electrode assembly can be manufactured, the solid polymer electrolyte membrane and the electrode catalyst layer can be separated under the operating conditions of the fuel cell (for example, hot water). There was a tendency that peeling of the film was likely to occur. Furthermore, when the electrolyte membrane described in Patent Document 1 is used in a fuel cell, flooding occurs, and the power generation performance of the fuel cell tends to decrease.
- the fuel cell for example, hot water
- the present invention has been made in view of the above problems, and can balance the power generation performance and water repellency that can produce a membrane-electrode assembly at a relatively low thermal transfer temperature, in which separation of the electrode catalyst layer in hot water does not easily occur.
- the object is to provide an excellent electrolyte membrane.
- Polymer (1) having a hydrophobic structural unit and a structural unit having a proton conductive group, and hydrophobic having no sulfonic acid group different from the hydrophobic structural unit of the polymer (1)
- An electrolyte membrane comprising a polymer (2) having a structural unit.
- the electrolyte membrane according to any one of [1] to [3], wherein the number average molecular weight of the polymer (2) is 1000 to 60000.
- the glass transition temperature (Tg) determined by differential scanning calorimetry (DSC, heating rate 20 ° C./min) of the polymer (2) is 220 ° C. or lower, and any one of [1] to [4] The electrolyte membrane described.
- a and D are each independently a direct bond, —O—, —S—, —CO—, —SO 2 —, —SO—, —CONH—, —COO—, — (CF 2 ) i — (i is 1 is an integer of 1 to 10), — (CH 2 ) j — (j is an integer of 1 to 10), —CR ′ 2 — (R ′ is an aliphatic hydrocarbon group, aromatic hydrocarbon group or halogen A hydrocarbon group)), a cyclohexylidene group or a fluorenylidene group, B independently represents —O— or —S—, R 1 to R 16 each independently represents a hydrogen atom, a halogen atom, a hydroxy group, a nitro group, a nitrile group or R 22 —E— (E is a direct bond, —O—, —S—, —CO—, — SO 2 —, —CONH—
- the hydrophobic structural unit contained in the polymer (1) includes an aromatic ring and has two bonds. Both of the two bonds are bonded to one aromatic ring, or An aromatic ring (a) and an aromatic ring (b) connected to the aromatic ring (a) via a single bond or at least one aromatic ring, the aromatic ring (a) and the aromatic ring (b) Each has one bond joined,
- the electrolyte membrane according to any one of [1] to [8], which is a structural unit.
- a membrane-electrode assembly in which a gas diffusion layer, a catalyst layer, the electrolyte membrane according to any one of [1] to [9], a catalyst layer, and a gas diffusion layer are laminated in this order.
- a polymer electrolyte fuel cell having the membrane-electrode assembly according to [10].
- an electrolyte membrane excellent in balance between power generation performance and water repellency which can produce a membrane-electrode assembly in which the catalyst layer is hardly peeled off in hot water at a relatively low thermal transfer temperature and in a short time. Can do. For this reason, by using such an electrolyte membrane, it is possible to easily produce a membrane-electrode assembly having excellent power generation performance, durability and the like, in which the catalyst layer is not easily damaged during the production of the membrane-electrode assembly. it can.
- an electrolyte membrane excellent in power generation performance, water repellency, electrode adhesion, and dimensional stability during a wet and dry cycle can be obtained, and further, such an electrolyte membrane can be used for a fuel cell.
- flooding can be suppressed, and a fuel cell excellent in power generation performance and durability can be obtained.
- FIG. 1 shows a transmission electron microscope (TEM) photograph of a cross section of the electrolyte membrane obtained in Example 6.
- TEM transmission electron microscope
- the electrolyte membrane of the present invention has a polymer (1) having a hydrophobic structural unit and a structural unit having a proton conductive group, and a sulfonic acid group different from the hydrophobic structural unit of the polymer (1).
- the polymer (2) which has a hydrophobic structural unit which does not carry out is contained.
- Such an electrolyte membrane is excellent in balance in power generation performance, water repellency, adhesion to an electrode, and dimensional stability during a dry and wet cycle. Further, by using such an electrolyte membrane, it is possible to produce a membrane-electrode assembly in which separation of the catalyst layer in hot water hardly occurs at a relatively low thermal transfer temperature.
- the water contact angle of the electrolyte membrane (surface) of the present invention is preferably 50 to 120 °, more preferably 50 to 110 °, and further preferably 60 to 100 °.
- the value of the water contact angle can be measured, for example, by the method described in the following examples.
- the electrolyte membrane is excellent in water repellency and adhesion to the electrode.
- the electrolyte membrane is used in a system in which water is generated during use, particularly in a fuel cell, flooding can be suppressed due to the water repellency of the surface, and adhesion to the electrode can be improved.
- a fuel cell excellent in power generation performance and durability can be obtained.
- the electrolyte membrane of the present invention has an ion exchange capacity measured by a method similar to the method described in Examples described later using the electrolyte membrane, preferably 0.5 to 5.0 meq / g, more preferably 1 .4 to 3.8 meq / g. It is preferable that the ion exchange capacity be in the above range because an electrolyte membrane having excellent proton conductivity and water resistance and high power generation performance can be obtained.
- the electrolyte membrane of the present invention has a dry film thickness of preferably 5 to 200 ⁇ m, more preferably 10 to 150 ⁇ m. Even when the electrolyte membrane of the present invention is a laminated membrane or a reinforced electrolyte membrane, these thicknesses are preferably within this range.
- the polymer (1) is not particularly limited as long as it has a hydrophobic structural unit and a structural unit having a proton conductive group, and may be a polymer or an oligomer.
- the structural unit having a proton conductive group may be simply a proton conductive group, and examples of the proton conductive group include a sulfonic acid group, a phosphonic acid group, a carboxy group, and a bissulfonylimide group. And sulfonic acid groups are preferred.
- the hydrophobic structural unit is not particularly limited.
- a polyaromatic hydrocarbon-based, polyether-based, polyetheretherketone-based, polyethersulfone-based, polyphenylenesulfide-based, having an aromatic ring in the main chain skeleton examples thereof include a polyimide-based or polybenzazole-based structural unit.
- the polymer (1) may be a known polymer, and is not particularly limited.
- Nafion registered trademark, manufactured by DuPont
- Aciplex registered trademark, manufactured by Asahi Kasei Kogyo Co., Ltd.
- FLUION registered trademark, manufactured by Asahi Glass Co., Ltd.
- a fluorinated carbon-based high molecular weight polymer having a sulfonic acid group polyaromatic hydrocarbon, polyether ether ketone, polyphenylene
- a high molecular polymer having an aromatic ring such as sulfide, polyimide or polybenzazole in the main chain skeleton and having a sulfonic acid group can be used.
- the number average molecular weight of the polymer (1) is preferably 10,000 to 1,000,000, more preferably 30,000 to 300,000, and the weight average molecular weight of the polymer (1) is preferably 10,000 to 1,000,000. More preferably, it is 50,000 to 400,000. It is preferable for the molecular weight to be in the above-mentioned range since the hot water resistance of the obtained electrolyte membrane tends to be improved.
- the method for measuring the number average molecular weight and the weight average molecular weight is as described in the following examples.
- the Tg of the polymer (1) by DSC is not particularly limited, but an electrolyte membrane excellent in stability in hot water can be obtained, and when operating at a high temperature of 80 ° C. or higher.
- the temperature is preferably 100 to 250 ° C., more preferably 120 to 250 ° C. from the viewpoint that a fuel cell having excellent creep resistance can be obtained.
- the ion exchange capacity of the polymer (1) is preferably 0.5 to 5.0 meq / g, more preferably 1.4 to 3.8 meq / g. When the ion exchange capacity is within the above range, an electrolyte membrane having excellent proton conductivity and power generation performance and sufficiently high water resistance can be obtained.
- the measuring method of the ion exchange capacity is as described in the following examples.
- the polymer (1) is a polymer composed of a hydrophilic segment (A1) including a structural unit having a proton conductive group and a hydrophobic segment (B1) including a hydrophobic structural unit.
- the polymer is preferably a polymer comprising a hydrophilic segment (A1) composed of a structural unit having a proton conductive group and a hydrophobic segment (B1) composed of a hydrophobic structural unit.
- the polymer (1) may be a block polymer or a random polymer, but an electrolyte membrane having more excellent power generation performance and dimensional stability during a dry / wet cycle can be obtained. From the viewpoint, a block copolymer of the hydrophilic segment (A1) and the hydrophobic segment (B1) is preferable.
- the hydrophilic segment (A1) and the hydrophobic segment (B1) are directly bonded without using a bonding group.
- a linking group exists between the hydrophilic segment (A1) and the hydrophobic segment (B1) and the linking group is an ether bond (—O—)
- the radical resistance of the obtained electrolyte membrane is inferior, The film tends to be easily deteriorated.
- the amount of each segment in the polymer (1) is determined according to desired properties such as the ion exchange capacity and number average molecular weight of the polymer.
- the amount of the segment (A1) is preferably 15 to 95% by weight, more preferably 25 to 85% by weight, and particularly preferably 35%.
- the amount of the segment (B1) is preferably 5 to 85% by weight, more preferably 15 to 75% by weight, and particularly preferably 25 to 65% by weight.
- the segment means an oligomer unit or a polymer unit in which 3 or more structural units constituting the segment are linked, and preferably 5 or more structural units constituting the segment are linked. More preferably, 10 or more are connected.
- the hydrophilic segment (A1) is not particularly limited as long as it has a proton conductive group and exhibits hydrophilicity.
- the hydrophilic segment (A1) has an aromatic ring in the main chain and a proton conductive group such as a sulfonic acid group.
- it preferably contains a sulfonic acid group and an aromatic ring, and has two bonds.
- the segment has a structural unit (i) having a connected aromatic ring (b) and one bond bonded to each of the aromatic ring (a) and the aromatic ring (b).
- the hydrophilic segment (A1) is such a segment, an electrolyte membrane having high continuity of the hydrophilic segment and high proton conductivity tends to be obtained as compared with the case where a conventional polymer is used.
- the hydrophilic segment (A1) may consist of only one type of structural unit or may contain two or more types of structural units.
- the number average molecular weight of the hydrophilic segment (A1) is preferably 1500 to 20000, more preferably 2500 to 10,000. Within the above range, an electrolyte membrane having high proton conductivity can be obtained, which is preferable.
- the measuring method of a number average molecular weight is as having described in the following Example.
- the structural unit (i) means, for example, a structural unit represented by the following formula (i).
- Ar, Ar a and Ar b are each independently a proton conductive group, a halogen atom, a nitrile group or R 22 -E- (E and R 22 are each independently the following formula (1) the same meaning as E and R 22 in which may be substituted with.), an aromatic group having a benzene ring, a condensed aromatic ring or nitrogen-containing heterocyclic ring, w is 0 or a positive integer, v Represents 0 or 1. However, Formula (i) has at least one proton conductive group. ]
- the divalent structural unit means a structural unit having two bonds.
- the hydrophilic segment (A1) is a structural unit represented by the following formula (5) (hereinafter referred to as “structural unit (5) from the viewpoint of obtaining an electrolyte membrane having high continuity of the hydrophilic segment and high proton conductivity”. It is preferable that it is a segment including the structural unit (5).
- Ar 11 , Ar 12 and Ar 13 are each independently a halogen atom, a nitrile group, a monovalent hydrocarbon group having 1 to 20 carbon atoms or a monovalent halogenated carbon atom having 1 to 20 carbon atoms.
- condensed aromatic ring examples include a naphthalene ring, a fluorene ring, a dibenzofuran ring and a dibenzothiophene ring.
- nitrogen-containing heterocycle examples include 5-membered and 6-membered ring structures containing a nitrogen atom. Further, the number of nitrogen atoms in the heterocycle is not particularly limited as long as it is 1 or more, and the heterocycle may contain an oxygen atom or a sulfur atom in addition to nitrogen.
- Ar 11 is preferably a benzene ring or biphenyl, and more preferably a benzene ring.
- Y and Z are each independently a direct bond, —O—, —S—, —CO—, —SO 2 —, —SO—, — (CH 2 ) u —, — (CF 2 ) u — (u is Represents an integer of 1 to 10), —C (CH 3 ) 2 — or —C (CF 3 ) 2 —, among which a direct bond, —O—, —CO—, SO 2 — or -(CF 2 ) u -is preferred.
- R 17 is independently a direct bond, —O (CH 2 ) p —, —O (CF 2 ) p —, — (CH 2 ) p — or — (CF 2 ) p — (p is an integer of 1 to 12 Among these, a direct bond, —O (CF 2 ) p —, and — (CF 2 ) p — are preferable in terms of proton conductivity.
- p is preferably an integer of 1 to 6, and preferably an integer of 1 to 4.
- R 18 and R 19 each independently represent a hydrogen atom or a protecting group. However, at least one of all R 18 and R 19 contained in the structural unit (5) is a hydrogen atom. Of these, R 18 and R 19 are preferably a hydrogen atom or a nitrogen-containing cation.
- the protecting group refers to an ion, atom or atomic group used for the purpose of temporarily protecting a reactive group (—SO 3 — or —SO 3 ⁇ ).
- a reactive group —SO 3 — or —SO 3 ⁇
- Specific examples include an alkali metal atom, an aliphatic hydrocarbon group, an alicyclic group, an oxygen-containing heterocyclic group, and a nitrogen-containing cation.
- x 1 independently represents an integer of 0 to 6, preferably an integer of 0 to 4, more preferably an integer of 0 to 2, and x 2 is an integer of 1 to 7, preferably an integer of 1 to 5, more preferably Represents an integer of 1 to 3, more preferably 1 or 2, a represents 0 or 1, b represents an integer of 0 to 20, preferably an integer of 0 to 3, more preferably 0 or 1, more preferably 0 is shown.
- the hydrophilic segment (A1) includes, for example, a structural unit having a phosphonic acid group (5 ′) as a structural unit having a proton conductive group other than the sulfonic acid group.
- aromatic structural units having a nitrogen-containing heterocycle described in JP 2011-089036 A and WO 2007/010731 described in JP 2011-089036 A and WO 2007/010731.
- the hydrophobic segment (B1) is not particularly limited as long as it is a hydrophobic segment.
- the hydrophilic segment (B1) may be composed of only one type of structural unit or may include two or more types of structural units.
- the number average molecular weight of the hydrophobic segment (B1) is preferably 1000 to 60000, more preferably 3000 to 40000. It is preferable for the number average molecular weight to be in the above-mentioned range since an electrolyte membrane having high hot water resistance and excellent mechanical strength can be obtained.
- the measuring method of a number average molecular weight is as describing in an Example.
- the hydrophobic segment (B1) preferably includes a hydrophobic segment having an aromatic ring in the main chain and not containing a proton conductive group such as a sulfonic acid group, and is more excellent in suppressing hot water swelling.
- a structural unit represented by the following formula (1) hereinafter also referred to as “structural unit (1)”
- a structural unit represented by the following formula (2) hereinafter referred to as “structural unit”.
- the segment is composed of at least one structural unit selected from the group consisting of the structural unit (1) and the structural unit (2).
- the polymer (1) contains any of the structural units (1) to (3 ′), in particular, the structural unit (1) or (2), the hydrophobicity of the polymer is remarkably improved. . Therefore, it is possible to obtain an electrolyte membrane having excellent hot water resistance while having proton conductivity similar to the conventional one. Moreover, when segment (B1) contains a nitrile group, an electrolyte membrane with high toughness and mechanical strength can be produced.
- the hydrophobic segment (B1) is preferably a structural unit including an aromatic ring and having two bonds, from the viewpoint of obtaining an electrolyte membrane excellent in suppressing hot water swelling. Both of the two bonds are bonded or have one aromatic ring (a) and an aromatic ring (b) connected to the aromatic ring (a) through a single bond or at least one aromatic ring , A segment having a structural unit (i ′) in which one bond is bonded to each of the aromatic ring (a) and the aromatic ring (b).
- the structural unit (i ′) means, for example, a structural unit represented by the following formula (i ′).
- Ar ′, Ar a1 and Ar b1 are each independently a halogen atom, a hydroxy group, a nitro group, a nitrile group or R 22 -E- (E and R 22 are each independently (Same as E and R 22 in (1)), which may be substituted with an aromatic group having a benzene ring, a condensed aromatic ring or a nitrogen-containing heterocyclic ring, and w is 0 or a positive integer.
- V represents 0 or 1.
- the hydrophilic segment (A1) is a structure represented by the formula (i), particularly a segment composed of the structural unit (5), and the hydrophobic segment (B1) is represented by the formula (i ′).
- a segment composed of the structure particularly the structural unit (1) and / or the structural unit (2)
- an electrolyte membrane excellent in power generation performance and dimensional stability during a wet / dry cycle tends to be obtained.
- the segment (B1) contains the structural unit (1)
- the segment (B1) includes the polymer (1) obtained by increasing the rigidity and increasing the aromatic ring density.
- the hot water resistance, radical resistance to peroxide, gas barrier properties, mechanical strength, dimensional stability, etc. of the electrolyte membrane can be improved.
- the hydrophobic segment (B1) may include one type of structural unit (1), or may include two or more types of structural units (1).
- At least one substitutable carbon atom constituting the aromatic ring may be replaced with a nitrogen atom, and R 21 is independently a halogen atom, a hydroxy group, a nitro group, a nitrile group or R 22 —.
- E- is a direct bond, —O—, —S—, —CO—, —SO 2 —, —CONH—, —COO—, —CF 2 —, —CH 2 —, —C (CF 3 ) 2 -or -C (CH 3 ) 2- ;
- R 22 represents an alkyl group, a halogenated alkyl group, an alkenyl group, an aryl group, a halogenated aryl group or a nitrogen-containing heterocyclic ring, and at least one of these groups one of the hydrogen atoms, further hydroxy group, a nitro group, may be substituted with at least one group selected from the group consisting of nitrile group, and R 22 -E-.
- the plurality of E may be the same or different, and a plurality of R 22 (however, The structure of the portion excluding the structural difference caused by the substitution may be the same or different. Similarly, in the present invention, when there are a plurality of groups represented by the same symbol in one formula, these groups may be the same or different. However, when several R ⁇ 22> is contained in one formula, it is preferable that the upper limit is five.
- the alkyl group, halogenated alkyl group, alkenyl group, aryl group and halogenated aryl group in R 22 are each an alkyl group having 1 to 20 carbon atoms and a halogenated alkyl group having 1 to 20 carbon atoms.
- the ring structure formed by combining a plurality of R 21 is not particularly limited, but may be a halogen atom, a nitrile group, a monovalent hydrocarbon group having 1 to 20 carbon atoms, or a monovalent halogenated carbon atom having 1 to 20 carbon atoms.
- examples thereof include an aromatic group, a cycloalkyl group having 3 to 20 carbon atoms such as a cyclopentyl group and a cyclohexyl group, and an oxygen-containing heterocyclic group which may be substituted with a hydrogen group.
- R 22 is preferably an aryl group.
- E is preferably a carbonyl group because of high polymerization activity during polymerization.
- c 1 and c 2 independently represent 0 or an integer of 1 or more, preferably 0 or 1, more preferably 0, and d represents an integer of 1 or more, preferably an integer of 1 to 300.
- e independently represents an integer of 0 to (2c 1 + 2c 2 +4), and an integer of 1 or more is from the viewpoint of improving the solubility of the resulting polymer and improving the adhesion to the electrode by reducing the softening temperature. preferable.
- the hydrophobic segment (B1) contains the structural unit (2) because radical resistance to peroxide and the like is improved and an electrolyte membrane excellent in power generation durability can be obtained. Moreover, when the hydrophobic segment (B1) contains the structural unit (2), an appropriate flexibility (flexibility) can be imparted to the segment (B1), and the electrolyte membrane containing the resulting polymer Toughness can be improved.
- the hydrophobic segment (B1) may include one type of structural unit (2) or may include two or more types of structural units (2).
- At least one substitutable carbon atom constituting the aromatic ring may be replaced with a nitrogen atom, and R 31 is independently a halogen atom, a hydroxy group, a nitro group, a nitrile group or R 22 —.
- E- (E and R 22 are each independently synonymous with E and R 22 in the formula (1)), and a plurality of R 31 may be bonded to form a ring structure.
- f represents 0 or an integer of 1 or more, preferably 0 or 1, more preferably 0, and g represents an integer of 0 to (2f + 4).
- the structural unit represented by Formula (2) is a structural unit other than the structural unit represented by Formula (1).
- the ring structure formed by combining a plurality of R 31 is not particularly limited, and examples thereof include structures similar to the ring structure formed by combining the plurality of R 21 .
- R 31 is preferably a nitrile group because the polymerization activity during copolymerization is high and the toughness and mechanical strength of the resulting electrolyte membrane are high.
- the segment (B1) is a segment containing the structural unit (1) and the structural unit (2)
- the segment (B1) is obtained by block copolymerization of the structural unit (1) and the structural unit (2).
- a structure may be used, but a structure in which the structural unit (1) and the structural unit (2) are randomly copolymerized is preferable in that the effects of the structural units (1) and (2) can be sufficiently obtained.
- the segment (B1) is a segment including the structural unit (1) and the structural unit (2)
- the total amount of the structural units (1) and (2) in the segment (B1) When the amount is 100 mol%, the amount of the structural unit (1) is preferably 50 to 99.9 mol%, more preferably 80 to 99.9 mol, from the viewpoint that the above-described effects become more remarkable. %, Particularly preferably 90 to 99.9 mol%, and the amount of the structural unit (2) is preferably 0.1 to 50 mol%, more preferably 0.1 to 20 mol%, particularly preferably 0. 1 to 10 mol%.
- the segment (B1) is a segment including the structural unit (1) and the structural unit (2)
- the total amount of the structural units (1) and (2) in the segment (B1) When the amount is 100% by weight, the amount of the structural unit (1) is preferably 33 to 99% by weight, more preferably 80 to 99% by weight, particularly preferably from the viewpoint that the above-described effects become more remarkable. Is 90 to 99% by weight, and the amount of the structural unit (2) is preferably 1 to 67% by weight, more preferably 1 to 20% by weight, and particularly preferably 1 to 10% by weight. Moreover, it is preferable that content of the said structural unit (1) exists in the said range also with respect to the said segment (B1) 100 weight%.
- the hydrophobic segment (B1) may include one type of structural unit (3 ′), or may include two or more types of structural units (3 ′).
- the segment (B1) is a segment including the structural unit (1) and the structural unit (3 ′)
- the total amount of the structural units (1) and (3 ′) in the segment (B1) When the amount is 100 mol%, the amount of the structural unit (1) is preferably 0.1 to 99.9 mol%, more preferably 0.5 To 99.5 mol%, particularly preferably 1 to 99 mol%, and the amount of the structural unit (3 ′) is preferably 0.1 to 99.9 mol%, more preferably 0.5 to 99. 5 mol%, particularly preferably 1 to 99 mol%.
- the segment (B1) is a segment including the structural unit (1) and the structural unit (3 ′)
- the amount of the structural unit (1) is preferably 0.1 to 99.9% by weight, more preferably 0.5% from the viewpoint that the above-described effects become more remarkable.
- the amount of the structural unit (3 ′) is preferably 0.1 to 99.9 wt%, more preferably 3 to 99.5 wt%, Particularly preferred is 10 to 99% by weight.
- content of the said structural unit (1) exists in the said range also with respect to the said segment (B1) 100 weight%.
- segment (B1) is a case where the segment (B1) is composed of only the structural unit (3 ').
- a ′ and D ′ are each independently a direct bond, —O—, —S—, —CO—, —SO 2 —, —SO—, —CONH—, —COO—, — (CF 2 ) i — (i is an integer from 1 to 10), — (CH 2 ) j — (j is an integer from 1 to 10), —CR ′ 2 — (R ′ is an aliphatic hydrocarbon) Group, an aromatic hydrocarbon group or a halogenated hydrocarbon group), a cyclohexylidene group or a fluorenylidene group, and among these, a direct bond, —O—, —CO—, —SO 2 —, — CR ′ 2 —, a cyclohexylidene group and a fluorenylidene group are preferred.
- R ′ an alkyl group and a perfluoroalkyl group are more preferable, and a methyl group and a trifluoromethyl group are more preferable.
- B ′ independently represents an oxygen atom or a sulfur atom, preferably an oxygen atom.
- R 1 ⁇ R 16 are each independently a hydrogen atom, a halogen atom, hydroxy group, nitro group, nitrile group or R 22 -E- (E and R 22 are each independently, E and R in formula (1) 22 And a plurality of groups of R 1 to R 16 may be bonded to form a ring structure.
- R 1 to R 16 are preferably each independently a hydrogen atom, a nitrile group or a t-butyl group.
- a ring structure formed by combining a plurality of groups of R 1 to R 16 is not particularly limited, but may be a halogen atom, a nitrile group, a monovalent hydrocarbon group having 1 to 20 carbon atoms, or a 1 to 20 carbon atoms. And an aromatic group, a cycloalkyl group having 3 to 20 carbon atoms such as a cyclopentyl group and a cyclohexyl group, and an oxygen-containing heterocyclic group which may be substituted with a monovalent halogenated hydrocarbon group.
- the benzene rings in formula (3 ′) may be bonded to each other through a direct bond, although not shown in the above examples.
- S and t each independently represent an integer of 0 to 4, preferably an integer of 0 to 2, and r represents 0 or an integer of 1 or more, preferably 0 to 100, more preferably 0 to 80.
- the polymer (1) can be synthesized by a conventionally known method, and is not particularly limited.
- the polymer (1) is a catalyst containing a transition metal and a compound that becomes the structural unit (eg, a dihalide having the structural unit).
- a sulfonic acid ester group or the like is converted to a sulfonic acid group, or a proton conductive group is introduced by a method such as sulfonation using a sulfonating agent. be able to.
- the polymer (2) is not particularly limited as long as it is a polymer having a hydrophobic structural unit having no sulfonic acid group different from the hydrophobic structural unit of the polymer (1), and may be a polymer. It may be an oligomer. Moreover, it is particularly preferable that the polymer (1) and the polymer (2) are not compatible with each other.
- the electrolyte membrane of the present invention contains the polymer (2) together with the polymer (1), the thermal transfer temperature when producing the membrane-electrode assembly is relatively low, and the transfer time is relatively low.
- the polymer (2) may have the same structural unit as the hydrophobic structural unit contained in the polymer (1), but a polymer incompatible with the polymer (1) is obtained, and An electrolyte membrane with a good balance between aqueous, electrode adhesion and dimensional stability during a wet / dry cycle can be obtained, and a membrane-electrode assembly that does not easily cause separation of the catalyst layer in hot water at a relatively low thermal transfer temperature. It is preferable that the polymer (1) does not have the same segment as the hydrophobic segment because it can be produced. When such a polymer (2) is used, an electrolyte membrane having a large water contact angle tends to be obtained.
- the incompatibility of the polymer (2) with the polymer (1) means that in the 2D or 3D-TEM image, the polymer (1) and the polymer (2) exist separately. Specifically, it can be confirmed from the presence of the polymer (2) separately in the polymer (1). Further, as a result of the incompatibility of the polymer (2) and the polymer (1), the polymer (2) tends to exist on both surfaces of the electrolyte membrane, and the water contact angle on the surface of the electrolyte membrane is increased. The polymer (2) is higher than the non-added film, and the film surface tends to be more hydrophobic. Therefore, it can be presumed that the polymers (1) and (2) are not compatible by measuring the water contact angle on the electrolyte membrane surface.
- the number average molecular weight of the polymer (2) is preferably 1000 to 60000, more preferably 3000 to 40000. It is preferable for the number average molecular weight to be within the above range since the hot water resistance of the resulting electrolyte membrane is improved.
- the measuring method of a number average molecular weight is as having described in the following Example.
- the Tg of the polymer (2) by DSC is not particularly limited, but a membrane-electrode assembly in which separation of the catalyst layer in hot water is unlikely to occur at a relatively low thermal transfer temperature. From the standpoint of production, etc., it is preferably 220 ° C. or lower, more preferably 20 to 220 ° C., and particularly preferably 30 to 220 ° C.
- the polymer (2) include aromatic polymers, fluorine-containing polymers, non-fluorine rubbers, etc., and there is a tendency that an electrolyte membrane having a large water contact angle can be obtained, and Aromatic polymers and fluorine-containing polymers are preferred from the standpoint that a membrane-electrode assembly in which the catalyst layer does not easily peel off in hot water can be produced at a relatively low thermal transfer temperature.
- the aromatic polymer is preferably an aromatic polyether polymer from the viewpoint of chemical durability and the like, and particularly preferable from the viewpoint of obtaining an electrolyte membrane excellent in water repellency and adhesion to the electrode.
- structural unit (3) a structural unit represented by the following formula (3) (hereinafter also referred to as “structural unit (3)”).
- the polymer (2) may contain one type of structural unit (3) or may contain two or more types of structural units (3).
- a and D are each independently a direct bond, —O—, —S—, —CO—, —SO 2 —, —SO—, —CONH—, —COO—, — (CF 2 I ⁇ (i is an integer of 1 to 10), — (CH 2 ) j — (j is an integer of 1 to 10), —CR ′ 2 — (R ′ is an aliphatic hydrocarbon group, aromatic Represents a hydrocarbon group or a halogenated hydrocarbon group), a cyclohexylidene group or a fluorenylidene group, and includes a direct bond, —O—, —CO—, —SO 2 —, —CR ′ 2 -, A cyclohexylidene group and a fluorenylidene group are preferred.
- R ′ examples include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, hexyl, octyl, decyl, octadecyl, ethylhexyl, phenyl, tri Examples thereof include a fluoromethyl group, a substituent in which some or all of the hydrogen atoms in these groups are halogenated, and the like.
- R ′ is more preferably an alkyl group or a perfluoroalkyl group, and further preferably a methyl group or a trifluoromethyl group.
- B independently represents —O— or —S—, preferably —O—.
- at least one of A, B and D is —O—, and when r is 0, s is an integer of 1 to 4.
- the R 1 ⁇ R 16 are each independently a hydrogen atom, a halogen atom, hydroxy group, nitro group, nitrile group or R 22 -E- (E and R 22 are each independently, E and R in formula (1) 22
- a plurality of groups of R 1 to R 16 may be bonded to form a ring structure.
- a ring structure formed by combining a plurality of groups of R 1 to R 16 is not particularly limited, but may be a halogen atom, a nitrile group, a monovalent hydrocarbon group having 1 to 20 carbon atoms, or a 1 to 20 carbon atoms.
- R 1 to R 16 are preferably a hydrogen atom, a nitrile group, and a t-butyl group, and are preferably a nitrile group from the viewpoint that an electrolyte membrane with high toughness and mechanical strength can be produced.
- S and t each independently represent an integer of 0 to 4, preferably an integer of 0 to 2, and r represents 0 or an integer of 1 or more, preferably 0 to 100, more preferably 0 to 80.
- the aromatic polyether polymer can be synthesized by a conventionally known method and is not particularly limited.
- a compound that becomes the structural unit (3) eg, a part of the structural unit (3).
- a dihalide having a structure or a dihydroxy compound can be synthesized by reacting in the presence of a catalyst or a solvent containing an alkali metal salt.
- a solvent-soluble fluoropolymer is preferably used.
- a fluorine-containing polymer is excellent in heat resistance, chemical resistance, mechanical properties, wear resistance, and the like, and has a feature of low gas permeability.
- an electrolyte membrane having a continuous phase composed of the polymer (1) and a dispersed phase composed of the fluoropolymer can be easily produced. Yes.
- a fluorine-containing polymer may be used individually by 1 type, and may use 2 or more types together.
- Such a solvent-soluble fluorine-containing polymer is not particularly limited, and examples thereof include vinylidene fluoride homo (co) polymers, fluoroolefin / hydrocarbon olefin copolymers, and fluoroacrylate copolymers. , Fluoroepoxy compounds and the like can be used.
- (1) vinylidene fluoride homo (co) polymer and (2) fluoroolefin / hydrocarbon olefin polymer are preferable from the viewpoint of use in combination with the polymer (1).
- the (2) fluoroolefin / hydrocarbon olefin polymer is a polymer different from the (1) vinylidene fluoride homo (co) polymer.
- the vinylidene fluoride homo (co) polymer is not particularly limited, but is preferably polyvinylidene fluoride, a copolymer of vinylidene fluoride and hexafluoropropylene, vinylidene fluoride and tetrafluoroethylene, And terpolymers of vinylidene fluoride, hexafluoropropylene, and tetrafluoroethylene, and alternating copolymers of tetrafluoroethylene, propylene, and vinylidene fluoride.
- Such a polyvinylidene fluoride homo (co) polymer is particularly excellent in impact resistance over a wide temperature range, and also in high temperature mechanical properties such as a high thermal deformation temperature, and almost all processing methods can be applied. It is preferable because of its characteristics.
- the fluoroolefin / hydrocarbon olefin copolymer is not particularly limited.
- an alternating copolymer of tetrafluoroethylene and propylene an alternating copolymer of chlorotrifluoroethylene and propylene, tetrafluoro Copolymers of ethylene and chlorotrifluoroethylene with ethyl vinyl ether, chloroethyl vinyl ether, isobutyl vinyl ether or hydroxyalkyl vinyl ether, copolymers of fluoroolefin and acrylate ester, copolymers of fluoroolefin and methacrylate ester A copolymer of fluoroolefin and carboxylic acid vinyl ester is preferred.
- the use of such a fluoroolefin / hydrocarbon olefin copolymer is desirable in that the toughness of the obtained electrolyte membrane can be improved.
- the polystyrene equivalent weight average molecular weight of the fluoropolymer by gel permeation chromatography is preferably 5,000 to 10,000,000, more preferably 50,000 to 1,000,000. If the molecular weight is too small, the excellent properties of the fluorine-containing polymer tend not to be exhibited. If the molecular weight is too large, the production of the electrolyte membrane tends to be difficult.
- the electrolyte membrane of the present invention may contain a metal compound or a metal ion in addition to the polymers (1) and (2).
- metal compounds or metal ions include aluminum (Al), manganese (Mn), niobium (Nb), tantalum (Ta), chromium (Cr), molybdenum (Mo), tungsten (W), iron (Fe), ruthenium ( Ru), nickel (Ni), tin (Sn), palladium (Pd), platinum (Pt), silver (Ag), cerium (Ce), vanadium (V), neodymium (Nd), praseodymium (Pr), samarium ( Examples thereof include metal compounds containing metal atoms such as Sm), cobalt (Co), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), and erbium (Er), or metal ions thereof. These may be used alone or in combination of
- the electrolyte membrane of the present invention is obtained by mixing a composition obtained by mixing the polymer (1), the polymer (2), an organic solvent, and the like with a die coat, spray coat, knife coat, roll coat, spin coat. It can be manufactured by including a step of coating on a substrate by a known method such as gravure coating. Specifically, after the composition is applied onto a substrate, the applied composition is dried, and if necessary, the obtained film is peeled from the substrate to obtain an electrolyte membrane.
- the amount of the polymer (1) used is such that, with respect to 100% by weight of the electrolyte membrane, a membrane-electrode assembly in which the catalyst layer does not easily peel off in hot water can be produced at a relatively low thermal transfer temperature.
- the amount is preferably 50 to 99.9% by weight, more preferably 80 to 99.5% by weight, and particularly preferably 90 to 99% by weight from the viewpoint that an electrolyte membrane excellent in water balance can be obtained.
- the amount of the polymer (2) used is preferably 0.1 to 50% by weight, more preferably 0.5 to 20% by weight, and particularly preferably based on 100% by weight of the electrolyte membrane for the same reason.
- the preferred range of the amount used is the same for 100% by weight of the polymer (1).
- the polymers (1) and (2) may be used singly or in combination of two or more.
- the substrate is not particularly limited as long as it is a substrate used when a normal composition is applied.
- a substrate made of resin, metal, glass or the like is used, and preferably a thermoplastic such as a PET film.
- a substrate made of resin is used.
- the organic solvent is preferably a solvent that dissolves or swells the polymers (1) and (2).
- a solvent that dissolves or swells the polymers (1) and (2).
- the composition of the mixture is preferably 95 to 25% by weight of an aprotic polar solvent, more preferably 90 to 25% by weight. %, And the other solvent is preferably 5 to 75% by weight, more preferably 10 to 75% by weight (however, the total is 100% by weight).
- the blending amount of the other solvent is within the above range, the effect of lowering the viscosity of the resulting composition is excellent.
- NMP is preferable as the aprotic polar solvent
- methanol having an effect of lowering the viscosity of the composition in a wide composition range is preferable as the other solvent.
- the drying is preferably performed by holding at a temperature of 50 to 200 ° C. for 0.1 to 10 hours.
- the drying may be performed in one step, or may be performed in two or more steps, that is, after the preliminary drying in advance and then the main drying.
- the drying may be performed under an inert gas atmosphere such as a nitrogen atmosphere or under reduced pressure as necessary.
- the electrolyte membrane of the present invention may be a single layer film or a multilayered film.
- the thickness of each layer is arbitrary. For example, one layer may be thick and the other layer may be thin.
- each layer may be the same or different.
- the reinforced electrolyte membrane can also be manufactured by using a porous base material or a sheet-like fibrous substance.
- the membrane-electrode assembly of the present invention is a membrane-electrode assembly in which a gas diffusion layer, a catalyst layer, an electrolyte membrane of the present invention, a catalyst layer, and a gas diffusion layer are laminated in this order.
- a catalyst layer for the cathode electrode is provided on one surface of the electrolyte membrane of the present invention
- a catalyst layer for the anode electrode is provided on the other surface
- each of the catalyst layers for the cathode electrode and the anode electrode is further provided. It is preferable that a gas diffusion layer is provided on each of the cathode electrode side and the anode electrode side in contact with the side opposite to the electrolyte membrane.
- the membrane-electrode assembly of the present invention has the electrolyte membrane of the present invention, even if a catalyst layer is provided on the electrolyte membrane by thermal transfer at the time of manufacturing the membrane-electrode assembly, it can be obtained at a low temperature in a short time. In this case, the catalyst layer is not easily damaged, and the power generation performance and durability are excellent.
- Such a membrane-electrode assembly of the present invention can be produced by a conventionally known method. Specifically, a composition to be a catalyst layer is formed on both surfaces of the electrolyte membrane of the present invention by a conventionally known method. The catalyst layer may be applied to form a catalyst layer, and a gas diffusion layer may be provided on the catalyst layer. Alternatively, the catalyst layer may be formed on a substrate such as a PET film in advance. You may manufacture by thermally transferring on both surfaces of the electrolyte membrane of invention, and providing a gas diffusion layer on the catalyst layer.
- the electrolyte membrane of the present invention it is possible to obtain a membrane-electrode assembly excellent in desired properties even when the temperature during thermal transfer is lowered, and even when a catalyst layer is formed by coating, Even when the catalyst layer is formed by the above, a membrane-electrode assembly in which the catalyst layer is hardly peeled off in hot water (for example, 70 to 100 ° C.) can be obtained.
- the gas diffusion layer examples include a porous substrate or a laminated structure of a porous substrate and a microporous layer.
- the gas diffusion layer is composed of a laminated structure of a porous base material and a microporous layer, the microporous layer is preferably in contact with the catalyst layer.
- the gas diffusion layer preferably contains a fluoropolymer in order to impart water repellency.
- the catalyst layer is preferably composed of a catalyst, an ion exchange resin, or the like.
- the catalyst include metal catalysts such as platinum, palladium, gold, ruthenium, iridium, cobalt and iron, and noble metal catalysts such as platinum, palladium, gold, ruthenium and iridium are preferably used.
- the metal catalyst may contain two or more elements such as an alloy or a mixture. As such a metal catalyst, a catalyst supported on carbon particles having a high specific surface area can be used.
- the ion exchange resin serves as a binder component for binding the catalyst, and efficiently supplies ions generated by a reaction on the catalyst to the electrolyte membrane at the anode electrode, and is supplied from the electrolyte membrane at the cathode electrode.
- a substance that efficiently supplies ions to the catalyst is preferable.
- the ion exchange resin is preferably a polymer having a proton exchange group in order to improve proton conductivity in the catalyst layer.
- Proton exchange groups contained in such polymers include sulfonic acid groups, carboxylic acid groups, and phosphoric acid groups, but are not particularly limited.
- the ion exchange resin known ones can be used without particular limitation, and examples thereof include Nafion
- the polymer (1) may be used as an ion exchange resin, and further a fluorine having a proton exchange group. It may be a polymer containing atoms, another polymer obtained from ethylene or styrene, a copolymer or a blend thereof.
- the catalyst layer may further contain additives such as carbon fiber and a resin not having an ion exchange group, if necessary.
- This additive is preferably a component having high water repellency, and examples thereof include a fluorine-containing copolymer, a silane coupling agent, a silicone resin, a wax, and polyphosphazene. It is a coalescence.
- the polymer electrolyte fuel cell of the present invention includes the membrane-electrode assembly. For this reason, the polymer electrolyte hydrogen fuel cell according to the present invention is particularly excellent in power generation performance, durability, etc. because flooding is suppressed.
- the polymer electrolyte fuel cell according to the present invention includes at least one electricity generating unit including a separator and located on both outer sides of at least one membrane-electrode assembly and its gas diffusion layer; It is preferable that the polymer electrolyte fuel cell includes a fuel supply unit that supplies an electricity generation unit; and an oxidant supply unit that supplies an oxidant to the electricity generation unit.
- separator those used in ordinary solid polymer fuel cells can be used. Specifically, a carbon type separator, a metal type separator, or the like can be used.
- the polymer electrolyte fuel cell of the present invention may be a single cell or a stack cell in which a plurality of single cells are connected in series.
- a known method can be used as the stacking method. Specifically, it may be planar stacking in which single cells are arranged in a plane, or bipolar in which single cells are stacked via separators each having a fuel or oxidant flow path formed on the back surface of the separator. Stacking may be used.
- a sample film was prepared from the polymer obtained in the following synthesis example, and the sample film was immersed in deionized water to completely remove the acid remaining in the film, and then 2 mL per 1 mg of the polymer.
- An aqueous hydrochloric acid solution was prepared by immersing in 2N saline solution and performing ion exchange. This hydrochloric acid aqueous solution was neutralized with a standard aqueous solution of 0.001N sodium hydroxide using phenolphthalein as an indicator.
- the sample membrane after ion exchange was washed with deionized water and vacuum dried at 110 ° C. for 2 hours, and the dry weight of the membrane was measured.
- Ion exchange capacity titration amount of sodium hydroxide (mmol) / dry weight of membrane (g)
- the polymer (oligomer) obtained in the following synthesis example was dissolved in an NMP buffer solution.
- NMP buffer solution Using the NMP buffer solution as an eluent, TOSOH HLC-8220 (manufactured by Tosoh Corporation) was used as an apparatus, and TSKgel ⁇ -M (column was used as a column).
- the number average molecular weight (Mn) and weight average molecular weight (Mw) in terms of polystyrene were determined by GPC using Tosoh Corporation.
- the NMP buffer solution was prepared at a ratio of NMP (3 L) / phosphoric acid (3.3 mL) / lithium bromide (7.83 g).
- ⁇ Glass-transition temperature ⁇ DSC Using a differential calorimeter, the temperature at which the heat capacity of the polymer (oligomer) obtained in the following synthesis example changes under nitrogen at a rate of temperature increase of 20 ° C./min was defined as the glass transition temperature.
- the AC resistance was obtained from the AC impedance measurement between the platinum wires. Specifically, the impedance at an alternating current of 10 kHz was measured in an environment of 70 ° C. and a relative humidity of 30%.
- a chemical impedance measurement system manufactured by NF Circuit Design Block Co., Ltd. was used as the resistance measurement device, and JW241 manufactured by Yamato Scientific Co., Ltd. was used as the constant temperature and humidity device. Five platinum wires were pressed at intervals of 5 mm.
- cathode electrode catalyst layer paste 80 g of zirconia balls (YTZ balls) with a diameter of 5 mm are put into a 200 mL plastic bottle, and platinum-supported carbon particles (“TEC10E50E” manufactured by Tanaka Kikinzoku Kogyo Co., Ltd., Pt: 45.6% by mass) 1.25 g, distilled 3.64 g of water, 11.91 g of n-propyl alcohol and Nafion D2020 (4.40 g) were added, and the mixture was stirred for 60 minutes with a paint shaker. Then, it filtered with a 100 mesh nylon mesh, the cathode electrode catalyst layer paste was obtained by removing a zirconia ball
- platinum-supported carbon particles (“TEC10E50E” manufactured by Tanaka Kikinzoku Kogyo Co., Ltd., Pt: 45.6% by mass) 1.25 g, distilled 3.64 g of water, 11.91 g of n-propyl alcohol and Nafion D2020 (4.
- Electrode catalyst layer sheet On a polytetrafluoroethylene (PTFE) sheet (manufactured by Nichias Corp., product name: Naflon tape TOMBO9001, thickness: 80 ⁇ m), a mask having a predetermined thickness and having an opening of 5 cm ⁇ 5 cm is disposed.
- the anode electrode catalyst layer paste obtained in (1) was applied with a doctor blade, and then dried at 120 ° C. for 60 minutes to prepare an anode catalyst layer sheet having a Pt catalyst application amount of 0.50 mg / cm 2 . Further, a cathode catalyst layer sheet having a Pt catalyst coating amount of 0.50 mg / cm 2 was prepared in the same manner using the cathode electrode catalyst layer paste.
- Electrolyst layer transferability evaluation Each 20 ⁇ m-thick electrolyte membrane obtained in Examples and Comparative Examples described later was peeled off from the PET film of the substrate and cut into a predetermined size, and then the obtained electrolyte membrane was prepared as 5 cm ⁇ 5 cm.
- Each of the electrode catalyst layer sheets for anode and cathode is sandwiched so that the catalyst layer side of each electrode catalyst layer sheet is on the electrolyte membrane side, heated with a precision hot press machine, and each electrode catalyst layer on the electrolyte membrane was thermally transferred.
- the pressure during the heating press is 30 kg / cm 2
- the pressing time is fixed at 5 minutes
- the heating temperature is changed to 110 ° C., 120 ° C., 130 ° C., 140 ° C., 150 ° C., 160 ° C., 170 ° C., 180 ° C.
- the minimum required temperature (temperature at which bonding is possible) at which both electrode catalyst layers could be transferred was comparatively investigated.
- GDL24BC manufactured by SGL CARBON was used as the gas diffusion layer.
- Air was supplied to the cathode electrode side of the obtained fuel cell for evaluation at a back pressure of 120 kPa and a utilization factor of 40%, pure hydrogen was supplied to the anode electrode side at a back pressure of 120 kPa and a utilization factor of 70%, and the cell temperature was 90 ° C.
- the cell voltage at a current density of 1.0 A / cm 2 was measured at a cathode electrode side relative humidity of 30% and an anode electrode side relative humidity of 30%.
- the stirred flask was placed in a 150 ° C. oil bath, and the reaction solution was heated to reflux at 150 ° C. Water produced by the reaction was trapped in a Dean-Stark tube. After 3 hours, when almost no water was observed, toluene was removed from the Dean-Stark tube out of the system. The reaction temperature was gradually raised to 200 ° C., and stirring was continued at that temperature for 3 hours. Then, 9.2 g (53 mmol) of 2,6-dichlorobenzonitrile was added, and the reaction was further continued for 5 hours.
- the reaction solution was allowed to cool, and diluted with 100 mL of toluene. Inorganic salts insoluble in the reaction solution were removed by filtration, and the filtrate was poured into 2 L of methanol to precipitate the product. The precipitated product was filtered and dried, then dissolved in 250 mL of tetrahydrofuran, and poured into 2 L of methanol for reprecipitation. The precipitated white powder was filtered and dried to obtain 109 g of the desired product. The Mn measured by GPC was 9,500. It was confirmed that the obtained compound was an oligomer represented by the following formula (11).
- the obtained filtrate was put into a 2 L three-necked flask equipped with a stirrer, a thermometer, and a nitrogen introduction tube, and then heated and stirred at 115 ° C., and 44 g (506 mmol) of lithium bromide was added. After stirring for 7 hours, the resulting liquid was poured into 5 L of acetone to precipitate the product. Next, the precipitate was washed with a 1N aqueous hydrochloric acid solution, washed with pure water, and dried to obtain 122 g of the target polymer. Mn of the obtained polymer was 54,000 and Mw was 135,000.
- the obtained polymer is presumed to be a polymer having a sulfonic acid group represented by the following formula (12). The ion exchange capacity of this polymer was 2.3 meq / g, and Tg was 190 ° C.
- m and k are values calculated from the charged amounts of raw materials forming the structural unit.
- the stirred flask was placed in a 150 ° C. oil bath, and the reaction solution was heated to reflux at 150 ° C. Water produced by the reaction was trapped in a Dean-stark tube. After 3 hours, when almost no water was observed, toluene was removed from the Dean-stark tube out of the system. The reaction temperature was gradually raised to 180 to 190 ° C., and stirring was continued at that temperature for 3 hours. Then, 24.6 g (0.14 mol) of 2,6-dichlorobenzonitrile was added, and the reaction was further continued for 5 hours.
- the reaction solution was allowed to cool and then added to 2401 mL of a methanol / 4 wt% sulfuric acid aqueous solution (5/1 (volume ratio)) to obtain a precipitate.
- the precipitated product was filtered and the filtrate was placed in 2401 mL of water and stirred at 55 ° C. for 1 hour.
- the liquid after stirring was filtered, and the residue was again put in 2401 mL of water, stirred at 55 ° C. for 1 hour, and then filtered.
- the filtrate was put into 2401 mL of methanol and stirred at 55 ° C. for 1 hour and then filtered.
- the filtrate was again put into 2401 mL of methanol and stirred at 55 ° C. for 1 hour and filtered.
- the filtrate was air-dried and then vacuum-dried at 80 ° C. to obtain 125 g (yield 90%) of the target product.
- Mn measured by GPC was 7,000. It was confirmed that the obtained compound was an oligomer represented by the formula (14).
- the obtained polymer was a polymer including a structure represented by the following formula (15).
- m and k are values calculated from the charged amounts of raw materials forming the structural unit.
- Addition system solution 1 was added to the obtained reaction system under nitrogen and heated to 60 ° C. with stirring, and then 8.78 g (134.4 mmol) of zinc and 1.47 g of bis (triphenylphosphine) nickel dichloride (2. 24 mmol) was added to further accelerate the polymerization, and the mixture was stirred at 80 ° C. for 3 hours. An exotherm and an increase in viscosity were observed with the reaction.
- the obtained solution was diluted with 498 mL of DMAc, and filtered using Celite as a filter aid.
- 25.93 g (298.56 mmol) of lithium bromide was added and reacted at 100 ° C. for 7 hours.
- the reaction solution was cooled to room temperature and poured into 3.3 L of water to obtain a liquid containing a coagulated product.
- the coagulated product was added to acetone and washed and filtered four times with stirring.
- the filtrate was added to 1N aqueous sulfuric acid solution, washed with stirring, and then filtered. This washing and filtration was repeated 7 times.
- the filtered material after filtration seven times was washed with deionized water until the pH of the washing solution reached 5 or higher and filtered.
- the obtained filtrate was dried at 75 ° C. for 24 hours to obtain a brown polymer powder.
- the molecular weight in terms of polystyrene measured by GPC of the polymer having a sulfonic acid group was 51,000 for Mn and 114,000 for Mw.
- the ion exchange capacity of this polymer was 2.24 meq / g, and Tg was 170 ° C.
- p is a value calculated from the charged amount of the raw material forming the structural unit.
- the precipitate obtained by filtering the coagulation liquid was washed with a small amount of methanol. 4. Add the resulting precipitate to The operation of adding 0 L of methanol and stirring and washing was repeated three times. The obtained product was dried to obtain 347 g (yield 88%) of the desired product (compound represented by the following formula (17)).
- the Mn in terms of polystyrene determined by GPC of the obtained target product was 4100, and Mw was 6600.
- x and y are values calculated from the charged amounts of raw materials forming the structural unit.
- the reaction solution was allowed to cool and then added to 3800 mL of a methanol / 4 wt% sulfuric acid aqueous solution (5/1 (volume ratio)) to obtain a precipitate.
- the precipitated product was filtered and the filtrate was placed in 2400 mL of water and stirred at 55 ° C. for 1 hour.
- the liquid after stirring was filtered, and the residue was again put in 3400 mL of water, stirred at 55 ° C. for 1 hour, and then filtered.
- the filtrate was put into 3400 mL of methanol, stirred for 1 hour at 55 ° C. and filtered, and the filtrate was again put into 3400 mL of methanol and stirred and filtered at 55 ° C. for 1 hour.
- the filtrate was air-dried and then vacuum-dried at 80 ° C. to obtain 318 g (yield 90%) of the target product.
- Mn measured by GPC of the obtained target product was 6,400. It was confirmed that the obtained compound was an oligomer represented by the following formula (18).
- the reaction solution was allowed to cool and then added to 2400 mL of a methanol / 4 wt% sulfuric acid aqueous solution (5/1 (volume ratio)) to obtain a precipitate.
- the precipitated product was filtered and the filtrate was placed in 2400 mL of water and stirred at 55 ° C. for 1 hour.
- the liquid after stirring was filtered, and the residue was again put in 2400 mL of water, stirred at 55 ° C. for 1 hour, and then filtered.
- the filtrate was put into 2401 mL of methanol and stirred at 55 ° C. for 1 hour and then filtered.
- the filtrate was again put into 2400 mL of methanol and stirred at 55 ° C. for 1 hour and filtered.
- the filtrate was air-dried and then vacuum-dried at 80 ° C. to obtain 187.6 g (yield 80%) of the target product.
- Mn measured by GPC of the obtained object was 8,500. It was confirmed that the obtained compound was an oligomer represented by the following formula (19).
- the obtained polymer was a polymer including a structure represented by the following formula (20).
- Addition system solution 2 was added to the obtained reaction system under nitrogen and heated to 60 ° C. with stirring, and then 6.60 g (101.0 mmol) of zinc and 1.10 g of bis (triphenylphosphine) nickel dichloride (1. 68 mmol) was added to further accelerate the polymerization, and the mixture was stirred at 80 ° C. for 3 hours. An exotherm and an increase in viscosity were observed with the reaction.
- the resulting solution was diluted with 320 mL of DMAc and filtered using Celite as a filter aid. 19.20 g (221.04 mmol) of lithium bromide was added to the filtrate, and the mixture was reacted at 100 ° C. for 7 hours.
- the reaction liquid was cooled to room temperature and poured into 2.4 L of water to obtain a liquid containing a coagulated product.
- the coagulum was added to acetone, washed with stirring, and then filtered. This washing and filtration was repeated 4 times.
- the filtrate after filtration four times was added to 1N aqueous sulfuric acid solution, washed with stirring, and then filtered. This washing and filtration was repeated 7 times.
- the filtered material after filtration seven times was washed with deionized water until the pH of the washing solution reached 5 or higher and filtered.
- the obtained filtrate was dried at 75 ° C. for 24 hours to obtain a brown polymer powder.
- the Mn in terms of polystyrene measured by GPC of the polymer having a sulfonic acid group was 71000, and Mw was 160000.
- the ion exchange capacity of this polymer was 2.35 meq / g, and Tg was 150 ° C.
- the film was cast on a die coater, preliminarily dried at 80 ° C. for 5 minutes, and then dried at 160 ° C. for 20 minutes.
- the dried PET film with a coating film was immersed in a large amount of distilled water overnight, the remaining NMP in the coating film was removed, and then air-dried.
- the polymer obtained in Synthesis Example 3 and Synthesis Example 9 were obtained.
- a PET film with an electrolyte membrane was obtained in which the polymer was contained at a mass ratio of 95/5 and the thickness of the electrolyte membrane was 20 ⁇ m.
- a film was formed in the same manner as in Example 1 except that a solution dissolved in 51 g of the solvent was used, and the polymer obtained in Synthesis Example 3 and the fluoropolymer were contained at a mass ratio of 95/5, and the thickness of the electrolyte membrane A PET film with an electrolyte membrane having a thickness of 20 ⁇ m was obtained.
- FIG. 1 shows a transmission electron micrograph of a cross section of the obtained electrolyte membrane.
- the black and white part spreading in the background is the polymer obtained in Synthesis Example 7 (polymer (1)), and the white, independent large mass part is the polymer obtained in Synthesis Example 9 (heavy polymer Combined (2)).
- the polymer obtained in Synthesis Example 7 and the polymer obtained in Synthesis Example 9 are not compatible with each other, and the polymer obtained in Synthesis Example 7 contains It was confirmed that the obtained polymer was dispersed. Other embodiments are likely to have this result.
- a film was formed in the same manner as in Example 1 except that the solution dissolved in 51 g of the solvent was used, and the polymer obtained in Synthesis Example 7 and the fluoropolymer were contained at a mass ratio of 95/5, and the thickness of the electrolyte membrane A PET film with an electrolyte membrane having a thickness of 20 ⁇ m was obtained.
- Example 1 and Example 2 are compared with Comparative Example 2, the polymer (1) and the polymer (2) having no hydrophobic structural unit different from the hydrophobic structural unit of the polymer (1) are shown. It has been found that a sufficient effect cannot be obtained when using and.
Abstract
Description
なお、特許文献1に具体的に記載されているのは、この電解質膜のみである。
さらに、前記特許文献1に記載の電解質膜を燃料電池に用いた場合、フラッディングが生じ、燃料電池の発電性能が低下する傾向にあった。
本発明の態様は、以下[1]~[11]に示すことができる。
[5] 前記重合体(2)の示差走査熱量測定(DSC、昇温速度20℃/分)によるガラス転移温度(Tg)が220℃以下である、[1]~[4]のいずれかに記載の電解質膜。
AおよびDはそれぞれ独立に、直接結合、-O-、-S-、-CO-、-SO2-、-SO-、-CONH-、-COO-、-(CF2)i-(iは1~10の整数である)、-(CH2)j-(jは1~10の整数である)、-CR'2-(R'は脂肪族炭化水素基、芳香族炭化水素基またはハロゲン化炭化水素基を示す。)、シクロヘキシリデン基またはフルオレニリデン基を示し、
Bは独立に、-O-または-S-を示し、
R1~R16はそれぞれ独立に、水素原子、ハロゲン原子、ヒドロキシ基、ニトロ基、ニトリル基またはR22-E-(Eは、直接結合、-O-、-S-、-CO-、-SO2-、-CONH-、-COO-、-CF2-、-CH2-、-C(CF3)2-または-C(CH3)2-を示し;R22は、アルキル基、ハロゲン化アルキル基、アルケニル基、アリール基、ハロゲン化アリール基または含窒素複素環を示し、これらの基の少なくとも1つの水素原子は、ヒドロキシ基、ニトロ基、ニトリル基およびR22-E-からなる群より選ばれる少なくとも1種の基で置換されていてもよい。)を示し、
R1~R16のうちの複数が結合して環構造を形成してもよく、
sおよびtはそれぞれ独立に、0~4の整数を示し、rは0または1以上の整数を示す。
但し、式(3)において、A、BおよびDのうち少なくとも1つは-O-であり、rが0の場合sは1~4の整数である。]
1つの芳香環に前記2つの結合手の両方が結合した、または、
1つの芳香環(a)、および、該芳香環(a)と単結合もしくは少なくとも1つの芳香環を介してつながった芳香環(b)を有し、芳香環(a)と芳香環(b)それぞれに結合手が1つずつ結合した、
構造単位である、[1]~[8]のいずれかに記載の電解質膜。
[11] [10]に記載の膜-電極接合体を有する固体高分子型燃料電池。
また、本発明によれば、発電性能、撥水性、電極との密着性および乾湿サイクル時の寸法安定性に優れる電解質膜を得ることができ、さらに、このような電解質膜を燃料電池に用いることで、フラッディングを抑制することができ、発電性能および耐久性等に優れる燃料電池を得ることができる。
本発明の電解質膜は、疎水性構造単位とプロトン伝導性基を有する構造単位とを有する重合体(1)、および、該重合体(1)の疎水性構造単位とは異なるスルホン酸基を有さない疎水性構造単位を有する重合体(2)を含有する。
このような電解質膜は、発電性能、撥水性、電極との密着性および乾湿サイクル時の寸法安定性にバランスよく優れる。また、このような電解質膜を用いることで、比較的低い熱転写温度で、熱水中での触媒層の剥離が生じにくい膜-電極接合体を製造することができる。
前記水接触角の値は、例えば、下記実施例に記載の方法で測定することができる。
このような電解質膜を、使用時に水が生成するような系、特に、燃料電池に用いる場合には、その表面の撥水性により、フラッディングを抑制することができ、また、電極との密着性に優れることにより、例えば、発電性能および耐久性等に優れる燃料電池を得ることができる。
前記重合体(1)は、疎水性構造単位とプロトン伝導性基を有する構造単位とを有すれば特に制限されず、ポリマーであってもよいし、オリゴマーであってもよい。
本発明において、プロトン伝導性基を有する構造単位は、単にプロトン伝導性基であってもよく、プロトン伝導性基としては、スルホン酸基、ホスホン酸基、カルボキシ基、ビススルホニルイミド基などが挙げられ、スルホン酸基が好ましい。
前記疎水性構造単位としては、特に制限されないが、例えば、芳香環を主鎖骨格に有する、ポリ芳香族炭化水素系、ポリエーテル系、ポリエーテルエーテルケトン系、ポリエーテルスルホン系、ポリフェニレンスルフィド系、ポリイミド系またはポリベンザゾール系構造単位が挙げられる。
前記セグメント(A1)および(B1)の合計量を100重量%とした場合、前記セグメント(A1)の量が、好ましくは15~95重量%、より好ましくは25~85重量%、特に好ましくは35~75重量%であり、前記セグメント(B1)の量が、好ましくは5~85重量%、より好ましくは15~75重量%、特に好ましくは25~65重量%である。
セグメント(A1)および(B1)となる原料化合物の使用量を調整することで、各セグメントの量が前記範囲にある重合体を得ることができ、これら原料化合物の使用量から、重合体(1)中の各セグメントの量を確認できる。
親水性セグメント(A1)としては、プロトン伝導性基を有し、親水性を示すセグメントであれば特に制限されないが、例えば、主鎖に芳香環を有し、スルホン酸基などのプロトン伝導性基を含有する親水性セグメントが挙げられ、発電性能および乾湿サイクル時の寸法安定性に優れる電解質膜が得られる等の点から、好ましくは、スルホン酸基および芳香環を含み、2つの結合手を有する構造単位であり、1つの芳香環に当該2つの結合手の両方が結合した、または、1つの芳香環(a)、および、該芳香環(a)と単結合もしくは少なくとも1つの芳香環を介してつながった芳香環(b)を有し、芳香環(a)と芳香環(b)それぞれに結合手が1つずつ結合した、構造単位(i)を有するセグメントである。
親水性セグメント(A1)が、このようなセグメントであると、従来の重合体を用いた場合に比べ、親水性セグメントの連続性が高く、プロトン伝導度の高い電解質膜が得られる傾向にある。
親水性セグメント(A1)は、1種類の構造単位のみからなってもよく、2種類以上の構造単位を含んでもよい。
R18およびR19としては、これらの中では、水素原子または含窒素カチオンが好ましい。
疎水性セグメント(B1)としては、疎水性を示すセグメントであれば特に制限されない。
親水性セグメント(B1)は、1種類の構造単位のみからなってもよく、2種類以上の構造単位を含んでもよい。
疎水性セグメント(B1)が、構造単位(1)を含有することにより、該セグメント(B1)の剛直性が高くなり、かつ芳香環密度が高くなることで、得られる重合体(1)を含む電解質膜の熱水耐性、過酸化物に対するラジカル耐性、ガスバリア性、機械的強度および寸法安定性等を向上させることができる。
疎水性セグメント(B1)は、1種類の構造単位(1)を含んでもよく、2種類以上の構造単位(1)を含んでもよい。
なお、R21がR22-E-であり、かつ、該R22がさらにR22-E-で置換される場合、複数のEは同一でも異なっていてもよく、複数のR22(ただし、置換によって生じる構造の差異を除く部分の構造)も同一でも異なっていてもよい。同様に、本発明において、一つの式中に同一の符号で表される基が複数存在する場合には、これらの基は、同一でも異なっていてもよい。ただし、一つの式中に複数のR22が含まれる場合、その上限は5個であることが好ましい。
Eとしては、重合時の重合活性が高いことなどからカルボニル基が好ましい。
eは独立に、0~(2c1+2c2+4)の整数を示し、得られる重合体の溶解性の向上や軟化温度の低減による電極等との密着性の向上の点で1以上の整数が好ましい。
前記疎水性セグメント(B1)が構造単位(2)を含むと、過酸化物などに対するラジカル耐性が向上し、発電耐久性に優れる電解質膜が得られると考えられるため好ましい。
また、前記疎水性セグメント(B1)が構造単位(2)を含有することにより、該セグメント(B1)に適度な屈曲性(柔軟性)を付与することができ、得られる重合体を含む電解質膜の靭性を向上させることができる。
疎水性セグメント(B1)は、1種類の構造単位(2)を含んでもよく、2種類以上の構造単位(2)を含んでもよい。
fは0または1以上の整数、好ましくは0または1、より好ましくは0を示し、gは0~(2f+4)の整数を示す。ただし、式(2)で表される構造単位は、式(1)で表される構造単位以外の構造単位である。
R31は、共重合時の重合活性が高いこと、得られる電解質膜の靭性および機械的強度が高くなることからニトリル基が好ましい。
また、前記構造単位(1)の含有量は、前記セグメント(B1)100重量%に対しても、前記範囲にあることが好ましい。
前記疎水性セグメント(B1)が構造単位(3')を含有することにより、該セグメント(B1)に適度な屈曲性(柔軟性)を付与することができ、得られる重合体を含む電解質膜の靭性を向上させることができる。
疎水性セグメント(B1)は、1種類の構造単位(3')を含んでもよく、2種類以上の構造単位(3')を含んでもよい。
また、前記構造単位(1)の含有量は、前記セグメント(B1)100重量%に対しても、前記範囲にあることが好ましい。
前記R1~R16はそれぞれ独立に、水素原子、ニトリル基およびt-ブチル基が好ましい。
前記重合体(1)は、従来公知の方法で合成することができ、特に制限されないが、例えば、前記構造単位となる化合物(例:前記構造単位を有するジハロゲン化物)を、遷移金属を含む触媒や溶媒の存在下で反応させ、必要によりスルホン酸エステル基などをスルホン酸基に変換する、または、スルホン化剤を用いてスルホン化する等の方法でプロトン伝導性基を導入することにより合成することができる。
重合体(2)は、該重合体(1)の疎水性構造単位とは異なるスルホン酸基を有さない疎水性構造単位を有する重合体であれば特に制限されず、ポリマーであってもよいし、オリゴマーであってもよい。また、前記重合体(1)と重合体(2)とは相溶しないことが特に好ましい。
本発明の電解質膜が、前記重合体(1)とともに、この重合体(2)を含むことで、特に、膜-電極接合体を製造する際の熱転写温度を比較的低く、転写時間を比較的短くすることができ、このような低温、短時間で膜-電極接合体を製造しても、熱水中での使用の際に、触媒層が電解質膜から剥離し難い膜-電極接合体を得ることができる。
さらに、水接触角が前記範囲にある電解質膜を得ることができ、撥水性に優れる電解質膜を得ることができるため、このような電解質膜を燃料電池に用いることで、フラッディングを抑制することができ、発電性能および耐久性等に優れる燃料電池を得ることができる。
また、前記重合体(2)と前記重合体(1)とが、相溶しない結果、電解質膜の両表面に、前記重合体(2)が存在しやすくなり、電解質膜表面の水接触角が、重合体(2)未添加膜に比べ上昇し、膜表面がより疎水性に変化する傾向にある。従って、電解質膜表面の水接触角を測定することで、重合体(1)と(2)とが相溶していないことが推測できる。
重合体(2)は、1種類の構造単位(3)を含んでもよく、2種類以上の構造単位(3)を含んでもよい。
前記R'としては、アルキル基またはパーフルオロアルキル基がより好ましく、メチル基またはトリフルオロメチル基がさらに好ましい。
なお、式(3)において、A、BおよびDのうち少なくとも1つは-O-であり、rが0の場合sは1~4の整数である。
R1~R16のうちの複数の基が結合して形成する環構造としては特に制限されないが、ハロゲン原子、ニトリル基、炭素数1~20の1価の炭化水素基もしくは炭素数1~20の1価のハロゲン化炭化水素基で置換されていてもよい、芳香族基、シクロペンチル基およびシクロヘキシル基などの炭素数3~20のシクロアルキル基、および、含酸素複素環基などが挙げられる。また、環構造を形成する場合には、前記の例示にはないが、直接結合を介して式(3)におけるベンゼン環同士を結合していてもよい。
R1~R16としては、水素原子、ニトリル基およびt-ブチル基が好ましく、靭性および機械的強度の高い電解質膜を製造できる等の点から、ニトリル基であることが好ましい。
前記芳香族ポリエーテル系重合体は、従来公知の方法で合成することができ、特に制限されないが、例えば、前記構造単位(3)となる化合物(例:前記構造単位(3)の一部の構造を有するジハロゲン化物やジヒドロキシ化合物)を、アルカリ金属塩を含む触媒や溶媒の存在下で反応させることにより合成することができる。
前記含フッ素ポリマーとしては、溶剤可溶性の含フッ素ポリマーを使用することが好ましい。このような含フッ素ポリマーは、耐熱性、耐薬品性、機械的特性、耐摩耗性などに優れ、ガス透過性が小さいという特徴を有する。
さらに、溶剤可溶性の含フッ素ポリマーを使用することにより、重合体(1)からなる連続相と含フッ素ポリマーからなる分散相とを有する電解質膜を容易に製造することができるという性質を有している。
含フッ素ポリマーは、1種単独で用いてもよく、2種以上を併用してもよい。
これらの中でも、前記重合体(1)と組み合わせて用いるという観点から、(1)フッ化ビニリデン系単独(共)重合体、および(2)フルオロオレフィン/炭化水素系オレフィン重合体が好ましい。なお、(2)フルオロオレフィン/炭化水素系オレフィン重合体は、前記(1)フッ化ビニリデン系単独(共)重合体とは異なる重合体である。
特に、このようなフルオロオレフィン/炭化水素系オレフィン共重合体を用いると、得られる電解質膜の靭性を向上させることができる等の点で望ましい。
本発明の電解質膜は、重合体(1)および(2)の他に、金属化合物または金属イオンを含んでもよい。金属化合物または金属イオンとしては、アルミニウム(Al)、マンガン(Mn)、ニオブ(Nb)、タンタル(Ta)、クロム(Cr)、モリブデン(Mo)、タングステン(W) 、鉄(Fe)、ルテニウム(Ru)、ニッケル(Ni)、スズ(Sn)、パラジウム(Pd)、白金(Pt)、銀(Ag)、セリウム(Ce)、バナジウム(V)、ネオジウム(Nd)、プラセオジウム(Pr)、サマリウム(Sm)、コバルト(Co)、ガドリニウム(Gd)、テルビウム(Tb)、ジスプロシウム(Dy)、ホルミウム(Ho)およびエルビウム(Er)等の金属原子を含む金属化合物またはこれらの金属イオンが挙げられる。
これらは、1種単独で用いてもよく、2種以上を併用してもよい。
本発明の電解質膜は、例えば、前記重合体(1)と、重合体(2)と、有機溶剤などとを混合して得られる組成物をダイコート、スプレーコート、ナイフコート、ロールコート、スピンコート、グラビアコートなどの公知の方法により基体上に塗布する工程を含むことにより製造することができる。具体的には、前記組成物を基体上に塗布した後、塗布した組成物を乾燥させ、必要により、得られる膜を基体から剥離することで、電解質膜を得ることができる。
また、前記重合体(2)の使用量は、電解質膜100重量%に対し、同様の理由から、好ましくは0.1~50重量%、より好ましくは0.5~20重量%、特に好ましくは1~10重量%であり、これら使用量の好ましい範囲は、重合体(1)100重量%に対しても同様である。
本発明の電解質膜を製造する際には、前記重合体(1)および(2)は、それぞれ、1種単独で用いてもよく、2種以上を併用してもよい。
これらの溶剤は、1種単独で、または2種以上を組み合わせて用いることができる。特に、得られる組成物の粘度の面から、NMPが好ましい。
なお、前記乾燥は、1段階で行ってもよく、2段階以上、つまり、予め予備乾燥した後、本乾燥してもよい。また、前記乾燥は、必要に応じて、窒素雰囲気下等の不活性ガス雰囲気下、もしくは減圧下にて乾燥を行ってもよい。
なお、積層膜の場合、各層の厚さは任意であり、例えば一方の層を厚く、他方の層を薄くしてもよい。また、各層は同一であっても、異なっていてもよい。
また、電解質膜を製造する際に、多孔質基材やシート状の繊維質物質を用いることで、補強された電解質膜を製造することもできる。
本発明の膜-電極接合体は、ガス拡散層、触媒層、本発明の電解質膜、触媒層およびガス拡散層がこの順で積層された膜-電極接合体である。具体的には、本発明の電解質膜の一方の面にはカソード電極用の触媒層、他方の面にはアノード電極用の触媒層を設け、さらにカソード電極用およびアノード電極用の各触媒層の電解質膜と反対側に接して、カソード電極側およびアノード電極側にそれぞれガス拡散層を設けたものであることが好ましい。
本発明の膜-電極接合体は、前記本発明の電解質膜を有するため、膜-電極接合体の製造時に、熱転写により電解質膜上に触媒層を設けたとしても、低温、短時間で、所望の膜-電極接合体が得られるため、その際に触媒層がダメージを受けにくく、発電性能および耐久性等に優れる。
このような本発明の膜-電極接合体は、従来公知の方法で製造することができるが、具体的には、本発明の電解質膜の両面に、触媒層となる組成物を従来公知の方法で塗布して触媒層を形成し、その触媒層の上にガス拡散層を設けることで製造してもよいし、予め、PETフィルムなどの基板上に触媒層を形成し、該触媒層を本発明の電解質膜の両面に熱転写し、その触媒層の上にガス拡散層を設けることで製造してもよい。
本発明の電解質膜を用いることで、熱転写の際の温度を低くしても、所望の特性に優れる膜-電極接合体を得ることができ、塗布により触媒層を形成しても、また、熱転写により触媒層を形成しても、熱水中(例えば、70~100℃)での触媒層の剥離が生じにくい膜-電極接合体を得ることができる。
触媒としては、白金、パラジウム、金、ルテニウム、イリジウム、コバルト、鉄などの金属触媒が挙げられ、白金、パラジウム、金、ルテニウム、イリジウムなどの貴金属触媒が好ましく用いられる。また、金属触媒は、合金や混合物などのように、2種以上の元素を含むものであってもよい。このような金属触媒は、通常、高比表面積カーボン微粒子に担持したものを用いることができる。
このようなポリマーに含まれるプロトン交換基としては、スルホン酸基、カルボン酸基、リン酸基などがあるが特に限定されるものではない。
本発明の固体高分子型燃料電池は、前記膜-電極接合体を含む。このため、本発明に係る固体高分子型水素燃料電池は、特に、フラッディングが抑制され、発電性能および耐久性等に優れる。
下記合成例で得られた重合体から試料膜を作成し、該試料膜を脱イオン水に浸漬することで、該膜中に残存している酸を完全に除去した後、重合体1mg当たり2mLの2N食塩水に浸漬してイオン交換させることにより塩酸水溶液を調製した。この塩酸水溶液を、フェノールフタレインを指示薬として、0.001N水酸化ナトリウムの標準水溶液にて中和滴定した。イオン交換後の試料膜を脱イオン水で洗浄し、110℃で2時間真空乾燥させて膜の乾燥重量を測定した。下記式に示すように、水酸化ナトリウムの滴定量と膜の乾燥重量とから、スルホン酸基の当量(以下「イオン交換容量」という。)を求めた。
イオン交換容量(meq/g)=水酸化ナトリウムの滴定量(mmol)/膜の乾燥重量(g)
下記合成例で得られた重合体(オリゴマー)をNMP緩衝溶液に溶解し、NMP緩衝溶液を溶離液として、装置としてTOSOH HLC-8220(東ソー(株)製)を、カラムとしてTSKgel α-M(東ソー(株)製)を用いたGPCによって、ポリスチレン換算の数平均分子量(Mn)と重量平均分子量(Mw)とを求めた。
NMP緩衝溶液は、NMP(3L)/リン酸(3.3mL)/臭化リチウム(7.83g)の比率で調製した。
DSC:示差熱量計を用い、窒素下、20℃/分の昇温速度により、下記合成例で得られた重合体(オリゴマー)の熱容量が変化する温度をガラス転移温度とした。
下記実施例および比較例で得られた電解質膜を用いて下記評価を実施した。結果を表1に示す。
下記実施例および比較例で得られた電解質膜の水接触角は協和界面科学(株)製CA-X接触角計を用い評価した。温度23±2℃、相対湿度50±5%の条件下で、電解質膜表面に水をシリンジで0.7mL滴下し、形成した液滴のなす角度、接触角θを測定した。電解質膜の両面10点ずつを測定し平均値を算出した。
下記実施例で得られた電解質膜の状態を、透過型電子顕微鏡を用いて観察した。実施例で得られた電解質膜の超薄切片を切り出し、該切片を硝酸鉛で染色した後、(株)日立製作所製HF-100FA透過型電子顕微鏡(2D-TEM)で観察することにより行った。
下記実施例および比較例で得られた電解質膜を5mm幅の短冊状にカットすることで得られた試料膜の表面に、白金線(Φ=0.5mm)を押し当て、恒温恒湿装置中で保持し、白金線間の交流インピーダンス測定から交流抵抗を求めた。具体的には、70℃、相対湿度30%の環境下で交流10kHzにおけるインピーダンスを測定した。抵抗測定装置として、(株)NF回路設計ブロック製のケミカルインピーダンス測定システムを用い、恒温恒湿装置には、(株)ヤマト科学製のJW241を使用した。白金線は、5mm間隔に5本押し当てた。その後、線間距離を5~20mmに変化させ、交流抵抗を測定した。線間距離と抵抗との関係を示す曲線の勾配から、試料膜の比抵抗を下記式から算出した。この比抵抗の逆数がプロトン伝導度に相当する。
比抵抗R(Ω・cm)=0.5(cm)×膜厚(cm)×抵抗線間勾配(Ω/cm)
200mLのポリボトルに直径5mmのジルコニアボール((株)ニッカトー製「YTZボール」)80gを入れ、白金ルテニウム担持カーボン粒子(田中貴金属工業(株)製「TEC61E54」、Pt:29.8質量%担持、Ru:23.2質量%担持)1.28g、蒸留水3.60g、n-プロピルアルコール12.02gおよびNafion D2020(DuPont社製、ポリマー濃度21%分散液、イオン交換容量1.08meq/g)3.90gを加え、ペイントシェーカーで60分間攪拌した。その後、100メッシュのナイロンメッシュでろ過し、ジルコニアボールを除去することで、アノード電極触媒層ペーストを得た。
次に、200mLのポリボトルに直径5mmのジルコニアボール(YTZボール)80gを入れ、白金担持カーボン粒子(田中貴金属工業(株)製「TEC10E50E」、Pt:45.6質量%担持)1.25g、蒸留水3.64g、n-プロピルアルコール11.91gおよびNafion D2020(4.40g)を加え、ペイントシェーカーで60分間攪拌した。その後、100メッシュのナイロンメッシュでろ過し、ジルコニアボールを除去することで、カソード電極触媒層ペーストを得た。
ポリテトラフルオロエチレン(PTFE)シート(ニチアス(株)製、製品名:ナフロンテープ TOMBO9001、厚み:80μm)上に、所定の厚さを有し、5cm×5cmの開口を有するマスクを配置し、上記で得られたアノード電極触媒層ペーストをドクターブレードにて塗布した後、120℃で60分間乾燥することで、Pt触媒塗布量が0.50mg/cm2のアノード触媒層シートを調製した。また、カソード電極触媒層ペーストを用い、同様の方法で、Pt触媒塗布量が0.50mg/cm2のカソード触媒層シートを調製した。
後述の実施例および比較例で得られた各20μm厚の電解質膜を、基材のPETフィルムから剥離し、所定のサイズにカットした後、得られた電解質膜を、先に調製した5cm×5cmのアノード用、カソード用の各電極触媒層シートで、各電極触媒層シートの触媒層側が電解質膜側になるように挟み、精密ホットプレス機にて加熱プレスし、電解質膜上に各電極触媒層を熱転写した。加熱プレスの際の圧力を30kg/cm2、プレス時間を5分で一定とし、加熱温度を110℃、120℃、130℃、140℃、150℃、160℃、170℃、180℃に変温し、両電極触媒層が転写できた最低必要温度(接合可能温度)を比較調査した。
後述の実施例および比較例で得られた電解質膜と、前記最低必要温度で熱転写した各電極触媒層との密着性を比較評価した。前記と同様の方法により作製した、電解質膜の両面に電極触媒層が形成された積層体を1000mLのガラス瓶に入れ、そこに約900mLの脱イオン水を加え、恒温乾燥器(アズワン(株)製、SONW-450)を用いて、95℃で24時間加温した。試験終了後、前記積層体を熱水中から取り出し、各電極触媒層(An:アノード、Ca:カソード)の剥離の有無を目視にて観察した。判定基準は以下のとおりである。
○:転写面5cm×5cmすべてにおいて剥離が生じていない
△:転写面5cm×5cmの一部(2cm2未満)で剥離が見られる
×:転写面5cm×5cmの2cm2~25cm2で剥離が見られる
ガス拡散層としてSGL CARBON社製のGDL24BCを用いた。
前記と同様の方法で、電解質膜に各触媒層を最低必要温度で熱転写した後、得られた積層体からPTFEシートを剥離し、得られた積層体を2枚のガス拡散層で挟み、圧力60kg/cm2下、160℃で20分間ホットプレスし、膜-電極接合体を作製した。得られた膜-電極接合体のガス拡散層上にガス流路を兼ねるセパレータを積層し、これを2枚のチタン製の集電体で挟み、さらにその外側にヒーターを配置し、有効面積25cm2の評価用燃料電池を作製した。
得られた評価用燃料電池のカソード電極側に背圧120kPa、利用率40%で空気を供給し、アノード電極側に背圧120kPa、利用率70%で純水素を供給し、セル温度を90℃、カソード電極側相対湿度を30%、アノード電極側相対湿度を30%として、電流密度1.0A/cm2でのセル電圧を測定した。
撹拌機および冷却管を備えた3Lの三つ口フラスコに、クロロスルホン酸(233.0g、2mol)を加え、続いて2,5-ジクロロベンゾフェノン(100.4g、400mmol)を加え、100℃のオイルバスで8時間反応させた。8時間後、反応液を砕氷(1000g)にゆっくりと注ぎ、酢酸エチルで抽出した。有機層を食塩水で洗浄し、次いで、硫酸マグネシウムで乾燥後、酢酸エチルを留去し、淡黄色の粗結晶(3-(2,5-ジクロロベンゾイル)ベンゼンスルホン酸クロリド)を得た。粗結晶は精製することなく、そのまま次工程に用いた。
攪拌機、温度計、Dean-Stark管、窒素導入管および冷却管をとりつけた1Lの三つ口フラスコに、2,6-ジクロロベンゾニトリル48.8g(284mmol)、2,2-ビス(4-ヒドロキシフェニル)-1,1,1,3,3,3-ヘキサフルオロプロパン89.5g(266mmol)および炭酸カリウム47.8g(346mmol)を量り取った。フラスコを窒素置換後、該フラスコにスルホラン346mLおよびトルエン173mLを加えて攪拌した。攪拌後のフラスコを150℃のオイルバスにつけ、反応液を150℃で加熱還流させた。反応によって生成する水はDean-Stark管にトラップした。3時間後、水の生成がほとんど認められなくなったところで、トルエンをDean-Stark管から系外に除去した。反応温度を200℃まで徐々に上げ、その温度で3時間攪拌を続けた後、2,6-ジクロロベンゾニトリル9.2g(53mmol)を加え、さらに5時間反応した。
得られた化合物は、下記式(11)で表されるオリゴマーであることを確認した。
攪拌機、温度計および窒素導入管をとりつけた1Lの三つ口フラスコに、合成例1で得られた化合物135.2g(337mmol)、合成例2で得られたオリゴマー48.7g(5.1mmol)、ビス(トリフェニルホスフィン)ニッケルジクロリド6.71g(10.3mmol)、ヨウ化ナトリウム1.54g(10.3mmol)、トリフェニルホスフィン35.9g(137mmol)および亜鉛53.7g(821mmol)を量り取った後、フラスコを乾燥窒素で置換した。ここにN,N-ジメチルアセトアミド(DMAc)430mLを加え、反応温度を80℃に保持しながら3時間攪拌を続けた後、DMAc730mLを加えて希釈し、不溶物を濾過により除去した。
3,5-ジクロロベンゼンスルホニルクロライド(114.65g、467mmol)を、ネオペンチルアルコール(45.30g、514mmol)のピリジン(300mL)溶液に、少量ずつ撹拌しながら15分かけて添加した。この間、反応温度は18~20℃に保った。反応混合物を冷却しながら、さらに30分撹拌した後、氷冷した10wt%HCl水溶液(1600mL)を添加した。水に不溶の成分を700mLの酢酸エチルで抽出し、1NのHCl水溶液で2回(各700mL)洗浄し、次いで、5wt%NaHCO3水溶液で2回(各700mL)洗浄し、MgSO4で乾燥させた。回転乾燥機を用いて溶媒を除去し、残渣を500mLのメタノールから再結晶させた。その結果、下記式(13)で表される3,5-ジクロロベンゼンスルホン酸ネオペンチルを、光沢のある無色の結晶(1H-NMRで99%を超える純度)として得た。収量105.98g、収率76%であった。
攪拌機、温度計、Dean-stark管、窒素導入管および冷却管をとりつけた1Lの三つ口フラスコに、2,6-ジクロロベンゾニトリル90.1g(0.52mol)、2,5-ジ-tert-ブチルハイドロキノン26.6g(0.12mol)、2-tert-ブチルハイドロキノン59.4g(0.36mol)および炭酸カリウム85.6g(0.62mol)を量り取った。フラスコを窒素置換後、該フラスコにスルホラン600mLおよびトルエン300mLを加えて攪拌した。攪拌後のフラスコを150℃のオイルバスにつけ、反応液を150℃で加熱還流させた。反応によって生成する水はDean-stark管にトラップした。3時間後、水の生成がほとんど認められなくなったところで、トルエンをDean-stark管から系外に除去した。反応温度を180~190℃まで徐々に上げ、その温度で3時間攪拌を続けた後、2,6-ジクロロベンゾニトリル24.6g(0.14mol)を加え、さらに5時間反応させた。
合成例4で得られた化合物28.73g(96.7mmol)と、合成例5で得られたオリゴマー23.29g(3.33mmol)、ビス(トリフェニルホスフィン)ニッケルジクロリド2.62g(4.0mmol)、トリフェニルホスフィン3.15g(12.0mmol)および亜鉛15.69g(240mmol)の混合物中に、乾燥したDMAc166mLを窒素下で加えた。
得られた混合物を撹拌下に加熱し(最終的には79℃まで加温)、3時間反応させた。反応途中で系中の粘度上昇が観察された。反応後の溶液をDMAc200mLで希釈した後、30分撹拌し、セライトを濾過助剤に用い、濾過した。
合成例4で得られた化合物22.54g(75.83mmol)と、トリフェニルホスフィン1.19g(4.55mmol)との混合物中に、脱水したDMAc55mLを窒素下で加えて添加系溶液1を調製した。
得られたオリゴマーの分子量を測定するために、反応系溶液を少量サンプリングした。得られたオリゴマーのGPCで測定したポリスチレン換算のMnは5500であった。
撹拌羽根、温度計、窒素導入管、Dean-stark管および冷却管を取り付けた3Lのセパラブル4つ口フラスコに、9,9-ビス(4-ヒドロキシフェニル)フルオレン92.8g(265mmol)、レゾルシノール87.4g(794mmol)、4,4’-ジフルオロベンゾフェノン205.4g(941mmol)、4-クロロ-4'-フルオロベンゾフェノン52.5g(224mmol)および炭酸カリウム175.6g(1271mmol)を加えた。次いで、DMAc1250mLおよびトルエン500mLを加えた。その後、155℃まで昇温し、反応によって生成する水をトルエンとの共沸により、Dean-stark管から取り除いた。水の生成が認められなくなるまで3時間反応した後、トルエンを系外に取り除きながら165℃まで昇温し、その後、160~165℃で5時間撹拌した。次に、4-クロロ-4’-フルオロベンゾフェノン30.4g(129mmol)を加え、再度、160~165℃で3時間撹拌した。
反応溶液をメタノール5.0Lに少量ずつ注ぎ、反応物を凝固させ、1時間攪拌した。凝固液をろ過して得られた沈殿物を、少量のメタノールで洗浄した。得られた沈殿物に5. 0Lのメタノールを加えて攪拌洗浄する操作を3回繰り返した。得られた生成物を乾燥し、347g( 収率88%)の目的物(下記式(17)で表される化合物)を得た。
得られた目的物のGPCで求めたポリスチレン換算のMnは4100、Mwは6600であった。
攪拌機、温度計、Dean-stark管、窒素導入管および冷却管をとりつけた1Lの三つ口フラスコに、2,6-ジクロロベンゾニトリル143.1g(832mmol)、4,4’-(1,3-フェニレンジイソプロピリデン)ビスフェノール266.1g(768mmol)および炭酸カリウム127.4g(922mmol)を量り取った。フラスコを窒素置換後、該フラスコにスルホラン960mLおよびトルエン480mLを加えて攪拌した。攪拌後のフラスコを150℃のオイルバスにつけ、反応液を150℃で加熱還流させた。反応によって生成する水はDean-stark管にトラップした。3時間後、水の生成がほとんど認められなくなったところで、トルエンをDean-stark管から系外に除去した。反応温度を180℃まで徐々に上げ、その温度で3時間攪拌を続けた後、2,6-ジクロロベンゾニトリル33.0g(192mmol)を加え、さらに5時間反応させた。
得られた目的物のGPCで測定したMnは6,400であった。得られた化合物は下記式(18)で表されるオリゴマーであることを確認した。
攪拌機、温度計、Dean-stark管、窒素導入管および冷却管をとりつけた1Lの三つ口フラスコに、ビス(4-クロロフェニル)スルホン149.3g(0.52mol)、ビス(4-ヒドロキシフェニル)スルホン120.1g(0.48mol)および炭酸カリウム85.6g(0.62mol)を量り取った。フラスコを窒素置換後、該フラスコにスルホラン700mLおよびトルエン350mLを加えて攪拌した。攪拌後のフラスコを150℃のオイルバスにつけ、反応液を150℃で加熱還流させた。反応によって生成する水はDean-stark管にトラップした。3時間後、水の生成がほとんど認められなくなったところで、トルエンをDean-stark管から系外に除去した。反応温度を180~190℃まで徐々に上げ、3時間攪拌を続けた後、ビス(4-クロロフェニル)スルホン40.2g(0.14mol)を加え、さらに5時間反応させた。
得られた目的物のGPCで測定したMnは8,500であった。得られた化合物は下記式(19)で表されるオリゴマーであることを確認した。
合成例4で得られた化合物28.40g(96.2mmol)、合成例9で得られたオリゴマー24.07g(3.76mmol)、ビス(トリフェニルホスフィン)ニッケルジクロリド2.62g(4.0mmol)、トリフェニルホスフィン2.10g(8.0mmol)および亜鉛15.69g(240mmol)の混合物中に、乾燥したDMAc168mLを窒素下で加えた。
反応系を撹拌下に加熱し(最終的には79℃まで加温)、3時間反応させた。反応途中で系中の粘度上昇が観察された。反応後の溶液をDMAc200mLで希釈し、30分撹拌した後、セライトを濾過助剤に用い、濾過した。
合成例4で得られた化合物16.42g(55.26mmol)、合成例9で得られたオリゴマー5.33g(0.83mmol)およびトリフェニルホスフィン0.88g(3.37mmol)の混合物中に、脱水したDMAc53mLを窒素下で加えて添加系溶液2を調製した。
得られたオリゴマーの分子量を測定するために、反応系溶液を少量サンプリングした。得られたオリゴマーのGPCで測定したポリスチレン換算のMnは7000であった。
合成例3で得られた重合体8.55gと、合成例9で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液をPETフィルムの上にダイコータにてキャスト塗工し、80℃で5分予備乾燥した後、160℃で20分乾燥した。乾燥後の塗膜付PETフィルムを大量の蒸留水に一晩浸漬し、塗膜中の残存NMPを取り除いた後、風乾し、合成例3で得られた重合体と合成例9で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例3で得られた重合体8.55gと、フッ素系重合体(ポリフッ化ビニリデン;型番301F、エルフ・アトケム社製)0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例3で得られた重合体とフッ素系重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例3で得られた重合体9.00gを、メタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例3の重合体からなる厚みが20μmである電解質膜付PETフィルムを得た。
合成例3で得られた重合体8.55gと、合成例2で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例3で得られた重合体と合成例2で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例6で得られた重合体8.55gと、合成例9で得られた重合体0.45gとメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例6で得られた重合体と合成例9で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例6で得られた重合体9.00gを、メタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例6の重合体からなる厚みが20μmである電解質膜付PETフィルムを得た。
市販のNafion D2020(デュポン(株)製、ポリマー濃度21%分散液、イオン交換容量1.08meq/g)42.9gに、30gのNMPを添加後、水および1-プロパノールを留去し溶媒置換することで、NafionのNMP溶液を得た。これに、メタノール40g、NMP30gを添加し、メタノール/NMP=40/60(質量比)の混合溶媒からなるNafion溶液を得た。次いで、合成例9で得られた重合体0.47gを、このNafion溶液に、添加、撹拌し、溶解させた。得られた溶液を用いた以外は実施例1と同様に製膜し、Nafionと合成例9で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、合成例8で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体と合成例8で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、合成例9で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体と合成例9で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、合成例2で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体と合成例2で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、合成例5で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体と合成例5で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、合成例10で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体と合成例10で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体8.55gと、フッ素系重合体(ポリフッ化ビニリデン;型番301F、エルフ・アトケム社製)0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7で得られた重合体とフッ素系重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例7で得られた重合体9.00gを、メタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例7の重合体からなる厚みが20μmである電解質膜付PETフィルムを得た。
合成例11で得られた重合体8.55gと、合成例8で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例11で得られた重合体と合成例8で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例11で得られた重合体9.00gを、メタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例11の重合体からなる厚みが20μmである電解質膜付PETフィルムを得た。
合成例12で得られた重合体8.55gと、合成例8で得られた重合体0.45gとをメタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例12で得られた重合体と合成例8で得られた重合体とが質量比95/5で含まれ、電解質膜の厚みが20μmである電解質膜付PETフィルムを得た。
合成例12で得られた重合体9.00gを、メタノール/NMP=40/60(質量比)の混合溶媒51gに溶解した溶液を用いた以外は実施例1と同様に製膜し、合成例12の重合体からなる厚みが20μmである電解質膜付PETフィルムを得た。
また、重合体(2)を添加しても著しく比抵抗を悪化させることが無く、密着性が向上することにより、電極と膜界面間のプロトン伝導性が向上し、発電性能を向上できることが分かった。
Claims (11)
- 疎水性構造単位とプロトン伝導性基を有する構造単位とを有する重合体(1)、および、該重合体(1)の疎水性構造単位とは異なるスルホン酸基を有さない疎水性構造単位を有する重合体(2)を含有する、電解質膜。
- 前記重合体(2)が芳香族ポリエーテル系重合体または含フッ素ポリマーである、請求項1に記載の電解質膜。
- 前記重合体(1)と前記重合体(2)の含有量の合計を100重量%とした際、前記重合体(1)の含有量が50~99.9重量%である、請求項1または2に記載の電解質膜。
- 前記重合体(2)の数平均分子量が1000~60000である、請求項1~3のいずれか1項に記載の電解質膜。
- 前記重合体(2)の示差走査熱量測定(DSC、昇温速度20℃/分)によるガラス転移温度(Tg)が220℃以下である、請求項1~4のいずれか1項に記載の電解質膜。
- 水接触角が50~120°である、請求項1~5のいずれか1項に記載の電解質膜。
- 前記重合体(2)は前記重合体(1)と相溶しない、請求項1~6のいずれか1項に記載の電解質膜。
- 前記重合体(2)が、下記式(3)で表される構造単位を含む芳香族ポリエーテル系重合体である、請求項1~7のいずれか1項に記載の電解質膜。
AおよびDはそれぞれ独立に、直接結合、-O-、-S-、-CO-、-SO2-、-SO-、-CONH-、-COO-、-(CF2)i-(iは1~10の整数である)、-(CH2)j-(jは1~10の整数である)、-CR'2-(R'は脂肪族炭化水素基、芳香族炭化水素基またはハロゲン化炭化水素基を示す。)、シクロヘキシリデン基またはフルオレニリデン基を示し、
Bは独立に、-O-または-S-を示し、
R1~R16はそれぞれ独立に、水素原子、ハロゲン原子、ヒドロキシ基、ニトロ基、ニトリル基またはR22-E-(Eは、直接結合、-O-、-S-、-CO-、-SO2-、-CONH-、-COO-、-CF2-、-CH2-、-C(CF3)2-または-C(CH3)2-を示し;R22は、アルキル基、ハロゲン化アルキル基、アルケニル基、アリール基、ハロゲン化アリール基または含窒素複素環を示し、これらの基の少なくとも1つの水素原子は、ヒドロキシ基、ニトロ基、ニトリル基およびR22-E-からなる群より選ばれる少なくとも1種の基で置換されていてもよい。)を示し、
R1~R16のうちの複数が結合して環構造を形成してもよく、
sおよびtはそれぞれ独立に、0~4の整数を示し、rは0または1以上の整数を示す。
但し、式(3)において、A、BおよびDのうち少なくとも1つは-O-であり、rが0の場合sは1~4の整数である。] - 前記重合体(1)に含まれる疎水性構造単位が、芳香環を含み、2つの結合手を有する構造であり、
1つの芳香環に前記2つの結合手の両方が結合した、または、
1つの芳香環(a)、および、該芳香環(a)と単結合もしくは少なくとも1つの芳香環を介してつながった芳香環(b)を有し、芳香環(a)と芳香環(b)それぞれに結合手が1つずつ結合した、
構造単位である、請求項1~8のいずれか1項に記載の電解質膜。 - ガス拡散層、触媒層、請求項1~9のいずれか1項に記載の電解質膜、触媒層およびガス拡散層がこの順で積層された膜-電極接合体。
- 請求項10に記載の膜-電極接合体を有する固体高分子型燃料電池。
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JP2016207609A (ja) * | 2015-04-28 | 2016-12-08 | 東洋紡株式会社 | 複合高分子電解質膜およびその製造方法ならびに膜電極接合体、燃料電池 |
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KR101878357B1 (ko) * | 2015-09-24 | 2018-07-16 | 주식회사 아모그린텍 | 연료전지용 분리막, 그의 제조방법 및 연료전지 전극 어셈블리 |
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