WO2016121168A1 - 水酸化物イオン伝導緻密膜及び複合材料 - Google Patents
水酸化物イオン伝導緻密膜及び複合材料 Download PDFInfo
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Definitions
- the present invention relates to a hydroxide ion conductive dense membrane and a composite material.
- Layered double hydroxide represented by hydrotalcite (hereinafter also referred to as LDH) is a group of substances having anions that can be exchanged between hydroxide layers. It is used as a catalyst, an adsorbent, and a dispersant in a polymer for improving heat resistance.
- LDH Layered double hydroxide represented by hydrotalcite
- it has been attracting attention as a material that conducts hydroxide ions, and addition to an electrolyte of an alkaline fuel cell or a catalyst layer of a zinc-air cell has been studied.
- Patent Documents 1 and 2 and Non-Patent Document 1 disclose an oriented LDH film.
- the oriented LDH film suspends the surface of a polymer base material horizontally in a solution containing urea and a metal salt to nucleate LDH. It is produced by forming and orientation growing. In each of the X-ray diffraction results of the oriented LDH thin films obtained in these documents, a strong peak of (003) plane is observed.
- zinc secondary batteries such as nickel zinc secondary batteries and zinc-air secondary batteries have been developed and studied for a long time, they have not yet been put into practical use. This is because the zinc constituting the negative electrode produces dendritic crystals called dendrite during charging, and this dendrite breaks through the separator and causes a short circuit with the positive electrode. Therefore, a technique for preventing a short circuit due to zinc dendrite in a zinc secondary battery such as a nickel zinc secondary battery or a zinc-air secondary battery is strongly desired.
- LDH dense body a dense bulk body of LDH (hereinafter referred to as an LDH dense body).
- LDH dense body a dense bulk body of LDH
- hydroxide ion conductivity for LDH dense bodies, it has been found that high conductivity is exhibited by conducting ions in the layer direction of LDH particles.
- LDH dense body has high resistance. Therefore, for practical use of LDH, it is desired to reduce the resistance by thinning.
- the oriented LDH films disclosed in Patent Documents 1 and 2 and Non-Patent Document 1 are not sufficient in terms of denseness.
- LDH dense film is desired.
- hydroxide ions in the electrolyte must move through the LDH dense membrane, while substances other than hydroxide ions (especially in zinc secondary batteries)
- a high degree of denseness is desired such that Zn causing zinc dendrite growth and carbon dioxide causing alkali carbonate precipitation in a zinc-air battery are not transmitted as much as possible.
- such high denseness is not limited to the LDH dense film, and it is also desired that the dense film is made of other materials having hydroxide ion conductivity regardless of organic materials and inorganic materials. Nor.
- the present inventors have recently made substances other than hydroxide ions (especially zinc dioxygen) by setting the He permeability per unit area to 10 cm / min ⁇ atm or less in a dense membrane having hydroxide ion conductivity.
- Zn which causes zinc dendrite growth in secondary batteries, can be significantly reduced, which makes it particularly suitable for certain applications such as battery separators (especially zinc secondary battery applications where zinc dendrite growth is a problem). It was found that a very high hydroxide ion conductive dense membrane can be provided.
- the object of the present invention is to significantly reduce the permeation of substances other than hydroxide ions (especially Zn that causes zinc dendrite growth in zinc secondary batteries), thereby reducing the use of battery separators and the like (especially zinc).
- An object of the present invention is to provide a highly dense hydroxide ion conductive dense film particularly suitable for zinc secondary battery applications in which dendrite growth is a problem.
- hydroxide ion conductive dense membrane having hydroxide ion conductivity and having a He permeability per unit area of 10 cm / min ⁇ atm or less.
- a composite material comprising a porous base material and the hydroxide ion conductive dense membrane of the above aspect provided on at least one surface of the porous base material.
- a battery comprising the hydroxide ion conductive dense membrane or the composite material as a separator.
- FIG. 1B is a schematic cross-sectional view of a sample holder used in the measurement system shown in FIG. It is a conceptual diagram which shows an example of a Zn permeation
- LDH layered double hydroxide
- Example B2 It is the XRD profile obtained with respect to the crystal phase of a sample in Example B2. It is a SEM image which shows the surface microstructure of the film
- Hydroxide ion conducting dense membrane present invention relates to hydroxide ion-conducting dense membrane.
- the hydroxide ion conductive dense membrane is preferably a layered double hydroxide dense membrane (LDH dense membrane), but is not limited thereto, and may be any dense membrane having hydroxide ion conductivity. It can be a film comprising an inorganic material and / or an organic material having hydroxide ion conductivity. In any case, it is desired that the hydroxide ion conductive dense membrane is a dense membrane that does not have water permeability. Although this dense membrane has hydroxide ion conductivity but does not have water permeability, it can function as a battery separator.
- LDH dense membrane layered double hydroxide dense membrane
- the dense membrane can be a very useful material as a solid electrolyte separator applicable to various battery applications such as metal-air batteries (for example, zinc-air batteries) and other various zinc secondary batteries (for example, nickel-zinc batteries).
- metal-air batteries for example, zinc-air batteries
- other various zinc secondary batteries for example, nickel-zinc batteries
- an appropriate repair agent for example, epoxy resin
- Such a repair agent need not necessarily have hydroxide ion conductivity.
- the hydroxide ion conductive dense membrane of the present invention is a dense membrane that should be essentially dense as described above, and has a particularly high level of denseness.
- the hydroxide ion conductive dense membrane of the present invention has a He permeability per unit area of 10 cm / min ⁇ atm or less, preferably 5.0 cm / min ⁇ atm or less, more preferably 1. 0 cm / min ⁇ atm or less.
- a dense film having a He permeability of 10 cm / min ⁇ atm or less can extremely effectively suppress the permeation of Zn in the electrolytic solution. For example, as shown in FIG.
- the dense membrane of the present invention has a remarkable suppression of Zn permeation, which is effective for the growth of zinc dendrites when used for the application of hydroxide ion conductive separators for secondary batteries such as zinc secondary batteries. In principle, it can be suppressed.
- the hydroxide ion conductive dense membrane of the present invention is extremely dense as described above, it is understood that the permeation of carbon dioxide that causes precipitation of alkali carbonate in a zinc-air battery can be significantly reduced.
- CO 2 molecules constituting carbon dioxide gas are much larger than He atoms constituting He gas, if the He permeability is low as described above, the CO 2 permeability is necessarily low. Therefore, it can be said that the dense membrane of the present invention is also suitable for metal-air batteries such as zinc-air batteries where precipitation of alkali carbonates in the electrolyte is a problem.
- the dense film of the present invention can effectively cope with such a problem.
- the He permeability includes a step of supplying He gas to one surface of the hydroxide ion conductive dense membrane to allow He gas to permeate the dense membrane, and calculating the He permeability to determine the density of the hydroxide ion conductive dense membrane. It is measured through a process for evaluating the sex.
- the He permeability is expressed by the following formula: F / (P ⁇ S) using the He gas permeation amount F per unit time, the differential pressure P applied to the dense film during He gas permeation, and the membrane area S through which the He gas permeates.
- He gas is supplied to one surface of the hydroxide ion conductive dense membrane, and the He gas is transmitted through the dense membrane.
- the supply of He gas is such that the He permeability per unit time F, the differential pressure P applied to the dense film during the He gas permeation, and the membrane area through which the He gas permeates so that the He permeability can be calculated in subsequent steps.
- the measurement is preferably performed in a measurement system that can identify S.
- An example of such a He transmission measurement system is shown in FIG. 1A.
- a He permeability measurement system 10 shown in FIG. 1A includes a pressure gauge 12, a flow meter 14, and a sample holder 16 holding a dense membrane.
- He gas is supplied to the sample holder 16 via the pressure gauge 12 and the flow meter 14, supplied to one surface of the dense film held by the sample holder 16, and passes through the dense film. And discharged from the other side.
- the dense film is preferably held by the sample holder 16 prior to the supply of the He gas.
- An example of the sample holder 16 is shown in FIGS. 1A and 1B.
- the sample holder 16 has a gas supply port 16a that allows introduction of He gas into the sample holder 16, and supply of He gas to a predetermined region on one surface of the dense film 18.
- a gas discharge port 16c that allows the He gas that has passed through the dense film 18 to be discharged.
- the He gas supplied from the gas supply port 16a to the sealed space 16b can be reliably transmitted through the dense film 18 and discharged from the gas discharge port 16c. Therefore, the permeation amount F of He gas per unit time can be accurately grasped.
- the sample holder 16 can be easily configured using easily available members.
- the adhesive 22 is interposed along the outer periphery of the dense film 18 (preferably provided in the form of a composite material formed on the porous substrate 20).
- the dense film 18 preferably provided in the form of a composite material formed on the porous substrate 20.
- sealing members 26a and 26b such as packing are disposed at the upper and lower ends of the jig 24.
- a flange or the like is provided from the outside of the sealing members 26a and 26b. It is configured to be sandwiched between support members 28a and 28b having openings.
- the sealed space 16b is partitioned by the dense film 18, the jig 24, the sealing member 26a, and the support member 28a.
- the dense film 18 is provided in the form of a composite material formed on the porous substrate 20
- the dense gas 18 side is arranged with the gas supply port 16a facing the supply pressure of He gas.
- the pair of support members 28a and 28b are preferably fastened to each other by fastening means 30 such as screws so that He gas does not leak from portions other than the gas discharge port 16c.
- a gas supply pipe 34 for supplying He gas can be connected to the gas supply port 16a through a joint 32 if desired. According to such a configuration, since assembly and disassembly can be easily performed, it is possible to efficiently evaluate He gas permeability for a large number of dense membranes.
- the He permeability is calculated to evaluate the denseness of the hydroxide ion conductive dense membrane.
- the calculation of the He permeability is calculated using F / (P ⁇ S) using the permeation amount F of He gas per unit time, the differential pressure P applied to the dense film when the He gas permeates, and the membrane area S through which the He gas permeates. It is calculated by the following formula.
- the unit of each parameter of F, P and S is not particularly limited, but the unit of He gas permeation amount F per unit time is cm 3 / min, the unit of differential pressure P is atm, and the unit of membrane area S is cm. 2 is preferable.
- the differential pressure P may be a value that allows the He gas to pass through the dense membrane, but it is preferable that the He gas is supplied so that the differential pressure P is within a range of 0.001 to 10 atm, more preferably. It is in the range of 0.01 to 3 atm, more preferably 0.01 to 0.9 atm, particularly preferably 0.05 to 0.9 atm.
- the dense film according to the present invention is very difficult to transmit (or hardly transmits) Zn under liquid contact.
- the dense membrane of the present invention preferably has a Zn permeation ratio of 10 m ⁇ 2 ⁇ h ⁇ 1 or less, more preferably 5.0 m ⁇ 2 when evaluated under water contact. • h ⁇ 1 or less, preferably 4.0 m ⁇ 2 ⁇ h ⁇ 1 or less, more preferably 3.0 m ⁇ 2 ⁇ h ⁇ 1 or less, more preferably 1.0 m ⁇ 2 ⁇ h ⁇ 1 or less.
- the low Zn permeation ratio means that the permeation of Zn can be extremely effectively suppressed in the electrolytic solution. For this reason, it is thought in principle that the growth of zinc dendrites can be effectively suppressed when used for applications of hydroxide ion conductive separators for secondary batteries such as zinc secondary batteries.
- the Zn transmission rate is determined through a step of allowing Zn to pass through the dense film for a predetermined time and a step of calculating the Zn transmission rate.
- the permeation of Zn into the dense membrane is achieved by bringing the first aqueous solution containing Zn into contact with one surface of the hydroxide ion conductive dense membrane and the second aqueous solution not containing Zn on the other surface of the dense membrane. Or it is performed by making water contact.
- the Zn permeation ratio is the Zn concentration C 1 of the first aqueous solution before the start of Zn permeation, the volume V 1 of the first aqueous solution before the start of Zn permeation, the second aqueous solution after the completion of Zn permeation, or the Zn of water. (C 2 ⁇ V 2 ) / (C 1 ) using the concentration C 2 , the second aqueous solution or water volume V 2 after the completion of Zn permeation, the Zn permeation time t, and the film area S through which Zn permeates.
- ⁇ is calculated by the equation of V 1 ⁇ t ⁇ S).
- the units of the parameters C 1 , C 2 , V 1 , V 2 , t and S are particularly limited as long as the units of the concentrations C 1 and C 2 are aligned and the units of the liquid amounts V 1 and V 2 are aligned.
- the unit of Zn transmission time t is h and the unit of film area S is m 2 .
- the Zn concentration C 1 of the first aqueous solution before Zn permeation is preferably within the range of 0.001 to 1 mol / L, more preferably 0.01 to 1 mol / L, and still more preferably 0.05 to 0. It is 8 mol / L, particularly preferably 0.2 to 0.5 mol / L, most preferably 0.35 to 0.45 mol / L.
- the Zn permeation time is preferably 1 to 720 hours, more preferably 1 to 168 hours, still more preferably 6 to 72 hours, and particularly preferably 12 to 24 hours.
- This Zn transmission rate can be an effective index for judging the difficulty of precipitation of zinc dendrite. This is because when a hydroxide ion conductive dense membrane is used as a separator in a zinc secondary battery, even if Zn is contained in the negative electrode electrolyte on one side of the dense membrane (zinc negative electrode side), the other side This is because, in principle, it is considered that the growth of zinc dendrite in the positive electrode electrolyte is effectively suppressed unless Zn permeates the positive electrode electrolyte (which originally does not contain Zn).
- hydroxide ion conductive dense membrane has a sufficiently high density suitable for a predetermined use such as a battery separator (especially a zinc secondary battery use where zinc dendrite growth is a problem). Whether or not can be evaluated reliably and with high accuracy.
- a first aqueous solution containing Zn is brought into contact with one surface of the hydroxide ion conductive dense membrane, and a second aqueous solution or water containing no Zn brought into contact with the other surface.
- the second aqueous solution allows Zn to permeate.
- the Zn concentration C 1 of the first aqueous solution before the start of Zn permeation the liquid volume V 1 of the first aqueous solution before the start of Zn permeation, so that the Zn permeation ratio can be calculated in the subsequent steps.
- a Zn concentration C 2 of the second aqueous solution or water after completion of Zn permeation, a volume V 2 of the second aqueous solution or water after termination of Zn permeation, and a membrane area S through which Zn permeates can be specified Is preferably carried out.
- An example of such a Zn transmission measuring device is shown in FIG. 2A.
- a measuring device 40 shown in FIG. 2A is provided on a sample holder 42 that holds a dense film in the measuring device, a first tank 44 provided on one side of the sample holder 42, and the other side of the sample holder 42. And a second tank 46.
- a first aqueous solution 48 containing Zn is accommodated in the first tank 44 so as to come into contact with one surface of the dense film, while a second aqueous solution 50 not containing Zn is made of the dense film in the second tank 46.
- the other surface is accommodated in a contactable manner. That is, the first aqueous solution 48 accommodated in the first tank 44 and the second aqueous solution 50 accommodated in the second tank 46 are completely partitioned by a dense film held in the sample holder 42. Accordingly, it is possible to reliably and accurately evaluate at what rate Zn contained in the first aqueous solution 48 permeates the second aqueous solution 50 through the dense film.
- the dense film is held in the measuring apparatus 40, particularly in the sample holder 42, prior to the permeation of Zn.
- An example of the sample holder 42 is shown in FIG. 2B.
- an adhesive 56 is provided along the outer periphery of the dense film 52 (preferably provided in the form of a composite material formed on the porous substrate 54). It is configured to be attached to a jig 58 having an opening at the center.
- sealing members 60a and 60b such as packing are disposed on both sides of the jig 58, and are sandwiched by flanges 62a and 62b from the outside of the sealing members 60a and 60b. .
- the flange 62a is preferably integrated with the first tank 44.
- the flange 62b is preferably integrated with the second tank 46.
- the dense film 52 is provided in the form of a composite material formed on the porous substrate 54, the dense film 52 side is disposed so as to be in contact with the first aqueous solution 48 containing Zn. , which is preferable in that Zn permeability can be more reliably evaluated.
- the pair of flanges 62a and 62b are preferably fastened to each other by fastening means 64 such as screws so that no liquid leakage occurs. According to such a configuration, since assembly and disassembly can be easily performed, Zn permeability can be efficiently evaluated for a large number of dense films.
- the first aqueous solution 48 is preferably an alkali metal hydroxide aqueous solution, and ZnO is preferably dissolved in the alkali metal hydroxide aqueous solution.
- the second aqueous solution 50 is preferably an alkali metal hydroxide aqueous solution in which ZnO is not dissolved, and more preferably the same type and the same as the first aqueous solution 48 except that ZnO is not dissolved.
- a preferred alkali metal hydroxide is potassium hydroxide.
- an alkali metal hydroxide aqueous solution such as an aqueous potassium hydroxide solution is a typical electrolyte used in an alkaline battery such as a zinc secondary battery
- an aqueous solution having a composition close to or equivalent to such an electrolyte Zn permeability can be evaluated with high accuracy under conditions close to or equivalent to the mode of use as a battery separator (particularly a zinc secondary battery separator).
- a compound containing Al is dissolved in both the first aqueous solution and the second aqueous solution, which are alkali metal hydroxide aqueous solutions, and are dissolved at the same concentration in both the first and second aqueous solutions. More preferably.
- Al which is a typical constituent element of LDH
- aqueous solution such as an aqueous potassium hydroxide solution
- Al which is a typical constituent element of LDH
- the Al may be dissolved in the electrolytic solution in some form, and can typically be dissolved in the electrolytic solution in the form of a metal ion, a hydroxide and / or a hydroxy complex.
- Al 3+ , Al (OH) 2+ , Al (OH) 2 + , Al (OH) 3 0 , Al (OH) 4 ⁇ , Al (OH) 5 2 ⁇ and the like are dissolved in the form of Al.
- the metal compound containing Al include aluminum hydroxide, ⁇ alumina, ⁇ alumina, boehmite, diaspore, hydrotalcite, and any combination thereof, more preferably aluminum hydroxide and / or ⁇ alumina. And most preferably aluminum hydroxide.
- the compound containing Al is preferably added so that the Al concentration in the first aqueous solution and the second aqueous solution is 0.001 mol / L or more, more preferably 0.01 mol / L or more, and still more preferably 0.1 mol. / L or more, particularly preferably 1.0 mol / L or more, most preferably 2.0 mol / L or more, more than 3.0 mol / L, or 3.3 mol / L or more.
- the upper limit of the concentration of Al in the electrolytic solution is not particularly limited, and may reach the saturation solubility of the Al compound, but is, for example, 20 mol / L or less or 10 mol / L or less.
- the hydroxide ion conductive dense film may be any dense film having hydroxide ion conductivity, for example, a film comprising an inorganic material and / or an organic material having hydroxide ion conductivity.
- An inorganic material having hydroxide ion conductivity has a general formula: M 2+ 1-x M 3+ x (OH) 2 A n ⁇ x / n ⁇ mH 2 O (wherein M 2+ is a divalent cation, M 3+ is a trivalent cation, a n-n-valent anion, n represents an integer of 1 or more, x is 0.1 ⁇ 0.4, m is represented by a is) 0 or more
- the layered double hydroxide is preferably included.
- a preferred hydroxide ion conductive dense film is a layered double hydroxide dense film, that is, an LDH dense film (hereinafter referred to as an LDH film).
- the hydroxide ion conductive dense membrane is desirably a membrane that does not have water permeability.
- the LDH film has a general formula: M 2+ 1-x M 3+ x (OH) 2 A n ⁇ x / n ⁇ mH 2 O (where M 2+ is a divalent cation and M 3+ is a trivalent cation) A n ⁇ is an n-valent anion, n is an integer of 1 or more, x is 0.1 to 0.4, and m is 0 or more), a layered double hydroxide (LDH) ), Preferably consisting mainly of such LDH.
- M 2+ may be any divalent cation, and preferred examples include Mg 2+ , Ca 2+ and Zn 2+ , and more preferably Mg 2+ .
- M 3+ may be any trivalent cation, but preferred examples include Al 3+ or Cr 3+ , and more preferred is Al 3+ .
- a n- can be any anion, but preferred examples include OH - and CO 3 2- .
- the general formula is an Mg 2+ at least M 2+, include Al 3+ in M 3+, to A n-OH - and / or CO preferably contains 3 2-.
- n is an integer of 1 or more, preferably 1 or 2.
- x is 0.1 to 0.4, preferably 0.2 to 0.35.
- m is a real number or an integer of 0 or more, typically more than 0 or 1 or more.
- the layered double hydroxide contained in the LDH film is composed of an assembly of a plurality of plate-like particles (that is, LDH plate-like particles), and the plate-like particles have a plate surface whose surface (base) It is preferably oriented in a direction that intersects the surface of the material substantially perpendicularly or obliquely. That is, the LDH crystal is known to have the form of a plate-like particle having a layered structure as shown in FIG. 3, but the substantially vertical or oblique orientation is a very advantageous characteristic for the LDH film. .
- the hydroxide ion conductivity in the direction in which the LDH plate-like particles are oriented is much higher than the conductivity in the direction perpendicular thereto. This is because of the conductivity anisotropy.
- the present inventors have found that in an LDH oriented bulk body, the conductivity (S / cm) in the orientation direction is an order of magnitude higher than the conductivity (S / cm) in the direction perpendicular to the orientation direction. It has gained.
- the substantially vertical or oblique alignment in the LDH film maximizes the conductivity anisotropy that the LDH alignment body can have in the layer thickness direction (that is, the direction perpendicular to the surface of the LDH film or the porous substrate).
- the conductivity in the layer thickness direction can be maximized or significantly increased.
- the LDH film since the LDH film has a layer form, lower resistance than the bulk form LDH can be realized. An LDH film having such an orientation easily conducts hydroxide ions in the layer thickness direction.
- the LDH plate-like particles are highly oriented in a substantially vertical direction in the LDH film. This high degree of orientation is confirmed by the fact that when the surface of the LDH film is measured by the X-ray diffraction method, the peak of the (003) plane is not substantially detected or smaller than the peak of the (012) plane. (However, when a porous substrate in which a diffraction peak is observed at the same position as the peak due to the (012) plane is used, the peak of the (012) plane due to the LDH plate-like particle is used. This is not the case).
- This characteristic peak characteristic indicates that the LDH plate-like particles constituting the LDH film are oriented in a substantially vertical direction (that is, a vertical direction or an oblique direction similar thereto, preferably a vertical direction) with respect to the LDH film. That is, the peak on the (003) plane is known as the strongest peak observed when X-ray diffraction is performed on non-oriented LDH powder. In an oriented LDH film, LDH plate-like particles are formed on the LDH film. On the other hand, the (003) plane peak is not substantially detected or is smaller than the (012) plane peak because of being oriented in a substantially vertical direction.
- the c-axis direction (00l) plane (l is 3 and 6) to which the (003) plane belongs is a plane parallel to the layered structure of the LDH plate-like particle.
- the LDH layered structure also faces the substantially vertical direction.
- the (00l) plane (l is 3 and 6) This is because the peak of) does not appear or becomes difficult to appear.
- the peak of the (003) plane tends to be stronger than the peak of the (006) plane when it exists, so it is easier to evaluate the presence / absence of orientation in the substantially vertical direction than the peak of the (006) plane.
- the oriented LDH film has a (003) plane substantially not detected or smaller than the (012) plane peak because it suggests a high degree of vertical orientation.
- the LDH alignment films disclosed in Patent Documents 1 and 2 and Non-Patent Document 1 are those in which the peak of the (003) plane is detected strongly, and are considered to be inferior in alignment in the substantially vertical direction. Moreover, it seems that it does not have high density.
- the hydroxide ion conductive dense membrane preferably LDH membrane
- the hydroxide ion conductive dense membrane preferably has a thickness of 100 ⁇ m or less, more preferably 75 ⁇ m or less, further preferably 50 ⁇ m or less, particularly preferably 25 ⁇ m or less, and most preferably 5 ⁇ m or less.
- Such a thin film can reduce the resistance of the dense film.
- the lower limit of the thickness of the dense film is not particularly limited because it varies depending on the application, but in order to ensure a certain degree of rigidity desired as a functional film such as a separator, the thickness is preferably 1 ⁇ m or more, more preferably Is 2 ⁇ m or more.
- the hydroxide ion conductive dense film may have a non-flat surface structure on at least one side.
- This non-planar surface structure is rich in gaps and / or undulations, resulting in a very high surface area structure. Therefore, when it is brought into contact with the electrolytic solution to be used as a separator, the area of the interface with the electrolytic solution increases, and as a result, the interface resistance can be lowered.
- An LDH separator having a low interface resistance with an electrolytic solution can be provided by providing a dense layer structure having hydroxide ion conductivity but not water permeability while having such a surface structure. It becomes possible.
- the non-flat surface structure preferably includes acicular particles protruding in a direction away from the dense film (typically in a direction substantially perpendicular to the dense film).
- the surface area can be significantly increased due to the presence of the acicular particles, and thereby the interface resistance when brought into contact with the electrolytic solution can be significantly more effectively reduced.
- the cross-sectional diameter of the acicular particles is preferably 0.01 to 0.5 ⁇ m, more preferably 0.01 to 0.3 ⁇ m.
- the height of the acicular particles is preferably 0.5 to 3.0 ⁇ m, more preferably 1 to 3 ⁇ m. In the present specification, the height of the acicular particles means the height of a portion protruding from the surface of the dense film as a reference.
- the non-flat surface structure comprises open pore coarse particles rich in voids.
- the presence of the open pore coarse particles can significantly increase the surface area, thereby more effectively reducing the interfacial resistance when in contact with the electrolyte.
- Particularly preferable open pore coarse particles are aggregated particles formed by aggregating a plurality of needle-like or plate-like particles so as to be entangled with each other to form a plurality of voids, and the aggregated particles in this form are marimo (diatomaceous) particles. It is particularly excellent in the effect of increasing the surface area.
- the open pore coarse particles preferably have a diameter of 0.5 to 30 ⁇ m in the direction parallel to the dense membrane, and more preferably 0.5 to 20 ⁇ m.
- the height of the open pore coarse particles is preferably 0.5 to 30 ⁇ m, more preferably 1 to 30 ⁇ m.
- the height of the open pore coarse particles means the height of a portion protruding from the surface of the dense membrane.
- the non-flat surface structure preferably includes both acicular particles and open pore coarse particles.
- the dense composite material film (preferably LDH film) is preferably provided on at least one surface of the porous substrate. That is, according to a preferred aspect of the present invention, there is provided a composite material comprising a porous substrate and the hydroxide ion conductive dense membrane provided on at least one surface of the porous substrate.
- the surface of the porous substrate mainly refers to the outermost surface of the plate surface when the rough shape of the porous substrate is viewed macroscopically as a plate, but is microscopically seen in the porous substrate. Needless to say, the surface of the hole existing in the vicinity of the outermost surface of the plate surface can be included.
- the porous substrate is preferably one that can form an LDH film on its surface, and its material and porous structure are not particularly limited. Typically, an LDH film is formed on the surface of a porous substrate, but an LDH film is formed on a nonporous substrate, and then the nonporous substrate is made porous by various known methods. Also good. In any case, it is preferable that the porous base material has a porous structure having water permeability in that the electrolyte solution can reach the LDH film when incorporated into a battery as a battery separator.
- the porous substrate is preferably composed of at least one selected from the group consisting of ceramic materials, metal materials, and polymer materials. More preferably, the porous substrate is made of a ceramic material.
- the ceramic material include alumina, zirconia, titania, magnesia, spinel, calcia, cordierite, zeolite, mullite, ferrite, zinc oxide, silicon carbide, and any combination thereof, and more preferable. Is alumina, zirconia, titania, and any combination thereof, particularly preferably alumina, zirconia (eg, yttria stabilized zirconia (YSZ)), and combinations thereof.
- YSZ yttria stabilized zirconia
- the metal material include aluminum and zinc.
- the polymer material include polystyrene, polyether sulfone, polypropylene, epoxy resin, polyphenylene sulfide, hydrofluorinated fluororesin (tetrafluorinated resin: PTFE, etc.), and any combination thereof. Any of the various preferred materials described above has alkali resistance as resistance to the electrolyte of the battery.
- the porous substrate preferably has an average pore diameter of 0.001 to 1.5 ⁇ m, more preferably 0.001 to 1.25 ⁇ m, still more preferably 0.001 to 1.0 ⁇ m, and particularly preferably 0.001. 0.75 ⁇ m, most preferably 0.001 to 0.5 ⁇ m.
- not having water permeability means “object to be measured” (ie, when the water permeability is evaluated by the “denseness determination test” employed in Example B5, which will be described later, or a technique or configuration equivalent thereto. It means that water that contacts one surface side of the LDH membrane and / or porous substrate does not permeate the other surface side.
- the average pore diameter can be measured by measuring the longest distance of the pores based on the electron microscope image of the surface of the porous substrate. The magnification of the electron microscope image used for this measurement is 20000 times or more, and all obtained pore diameters are arranged in the order of size, and the upper 15 points and the lower 15 points from the average value. The average pore size can be obtained by calculating the average value of minutes.
- a length measurement function of an electron microscope software, image analysis software (for example, Photoshop, manufactured by Adobe) or the like can be used.
- the surface of the porous substrate preferably has a porosity of 10 to 60%, more preferably 15 to 55%, still more preferably 20 to 50%. By setting it within these ranges, it is possible to form an LDH film that is so dense that it does not have water permeability (preferably water permeability and air permeability) while ensuring the desired water permeability in the porous substrate.
- the porosity of the surface of the porous substrate is adopted because it is easy to measure the porosity using the image processing described below, and the porosity of the surface of the porous substrate. This is because it can be said that it generally represents the porosity inside the porous substrate. That is, if the surface of the porous substrate is dense, the inside of the porous substrate can be said to be dense as well.
- the porosity of the surface of the porous substrate can be measured as follows by a technique using image processing. That is, 1) an electron microscope image (a magnification of 10,000 times or more) of the surface of the porous substrate is acquired, and 2) a gray scale electron microscope image is read using image analysis software such as Photoshop (manufactured by Adobe). ) Create a black-and-white binary image by the procedure of [Image] ⁇ [Tone Correction] ⁇ [2 Gradation], and 4) Porosity (the value obtained by dividing the number of pixels occupied by the black part by the total number of pixels in the image) %).
- the porosity measurement by this image processing is preferably performed for a 6 ⁇ m ⁇ 6 ⁇ m region on the surface of the porous substrate. In order to obtain a more objective index, three arbitrarily selected regions are used. It is more preferable to employ the average value of the obtained porosity.
- the LDH film and the LDH-containing composite material according to the present invention are prepared by (a) preparing a porous substrate, and (b) optionally adding a starting material capable of giving an LDH crystal growth starting point to the porous substrate. It can be preferably produced by uniformly adhering and (c) subjecting the porous substrate to hydrothermal treatment to form an LDH film.
- the porous substrate is as described above, and is preferably composed of at least one selected from the group consisting of ceramic materials, metal materials, and polymer materials. More preferably, the porous substrate is made of a ceramic material.
- the ceramic material include alumina, zirconia, titania, magnesia, spinel, calcia, cordierite, zeolite, mullite, ferrite, zinc oxide, silicon carbide, and any combination thereof, and more preferable. Is alumina, zirconia, titania, and any combination thereof, particularly preferably alumina, zirconia (eg, yttria stabilized zirconia (YSZ)), and combinations thereof.
- YSZ yttria stabilized zirconia
- the density of the LDH film tends to be improved.
- the porous substrate is more preferably composed of a ceramic material.
- the porous substrate made of a ceramic material may be a commercially available product or may be prepared according to a known technique, and is not particularly limited.
- ceramic powder for example, zirconia powder, boehmite powder, titania powder, etc.
- methylcellulose, and ion-exchanged water are kneaded at a desired blending ratio, the obtained kneaded product is subjected to extrusion molding, and the resulting molded body is obtained.
- a porous substrate made of a ceramic material can be prepared by drying at 70 to 200 ° C. for 10 to 40 hours and then firing at 900 to 1300 ° C. for 1 to 5 hours.
- the blending ratio of methylcellulose is preferably 1 to 20 parts by weight with respect to 100 parts by weight of the ceramic powder.
- the mixing ratio of the ion exchange water is preferably 10 to 100 parts by weight with respect to 100 parts by weight of the ceramic powder.
- a starting material that can provide a starting point for crystal growth of LDH may be uniformly attached to the porous substrate. After the starting material is uniformly attached to the surface of the porous substrate in this way, the subsequent step (c) is performed, so that a highly densified LDH film can be uniformly formed on the surface of the porous substrate. It can be formed uniformly.
- an origin include a chemical species that provides an anion that can enter between the layers of LDH, a chemical species that provides a cation that can be a constituent element of LDH, or LDH.
- the starting point of crystal growth of LDH can be a chemical species that provides anions that can enter between layers of LDH.
- examples of such anions include CO 3 2 ⁇ , OH ⁇ , SO 3 ⁇ , SO 3 2 ⁇ , SO 4 2 ⁇ , NO 3 ⁇ , Cl ⁇ , Br ⁇ , and any combination thereof. It is done. Therefore, the starting material that can provide such a starting point may be uniformly attached to the surface of the porous substrate by an appropriate method according to the type of the starting material.
- metal cations such as Mg 2+ and Al 3+ can be adsorbed on the surface of the porous substrate to generate LDH nuclei. Therefore, by performing the subsequent step (c), a highly densified LDH film can be uniformly formed on the surface of the porous substrate without unevenness.
- the starting material can be attached by attaching a polymer to the surface of the porous substrate and then introducing a chemical species that gives an anion to the polymer.
- the anion is preferably SO 3 ⁇ , SO 3 2 ⁇ and / or SO 4 2 ⁇ , and introduction of a chemical species giving such an anion into the polymer is performed by sulfonation treatment.
- Polymers that can be used are anionizable (especially sulfonated) polymers, examples of such polymers include polystyrene, polyethersulfone, polypropylene, epoxy resins, polyphenylene sulfide, and any combination thereof. .
- the aromatic polymer is preferable in that it is easily anionized (particularly sulfonated).
- aromatic polymer examples include polystyrene, polyethersulfone, epoxy resin, polyphenylene sulfide, and any of them. Combinations are mentioned.
- the most preferred polymer is polystyrene.
- the adhesion of the polymer to the porous substrate is performed by using a solution in which the polymer is dissolved (hereinafter referred to as a polymer solution) as the surface of the porous substrate (preferably, the outermost surface of the plate-like outline of the porous substrate). ) Is preferably applied by coating.
- the polymer solution can be easily prepared, for example, by dissolving a polymer solid (for example, a polystyrene substrate) in an organic solvent (for example, a xylene solution). It is preferable to prevent the polymer solution from penetrating into the porous substrate because it is easy to achieve uniform coating.
- the polymer solution is preferably attached or applied by spin coating because it can be applied uniformly.
- the spin coating conditions are not particularly limited.
- the spin coating may be performed at a rotational speed of 1000 to 10000 rpm for about 60 to 300 seconds including dripping and drying.
- the sulfonation treatment may be performed by immersing the porous substrate to which the polymer is attached in a sulfonateable acid such as sulfuric acid (for example, concentrated sulfuric acid), fuming sulfuric acid, chlorosulfonic acid, and sulfuric anhydride.
- a sulfonateable acid such as sulfuric acid (for example, concentrated sulfuric acid), fuming sulfuric acid, chlorosulfonic acid, and sulfuric anhydride.
- the technology may be used.
- the immersion in the sulfonateable acid may be performed at room temperature or high temperature (for example, 50 to 150 ° C.), and the immersion time is not particularly limited, but is, for example, 1 to 14 days.
- the starting material can be attached by treating the surface of the porous substrate with a surfactant containing a chemical species that gives an anion as a hydrophilic group.
- the anion is preferably SO 3 ⁇ , SO 3 2 ⁇ and / or SO 4 2 ⁇ .
- a typical example of such a surfactant is an anionic surfactant.
- Preferred examples of the anionic surfactant include a sulfonic acid type anionic surfactant, a sulfate type anionic surfactant, and any combination thereof.
- sulfonic acid type anionic surfactant examples include naphthalene sulfonic acid Na formalin condensate, polyoxyethylene sulfosuccinic acid alkyl 2Na, polystyrene sulfonic acid Na, dioctyl sulfosuccinic acid Na, polyoxyethylene lauryl ether sulfate triethanolamine. It is done.
- sulfate ester type anionic surfactant include polyoxyethylene lauryl ether sulfate Na.
- the treatment of the porous substrate with the surfactant is not particularly limited as long as it is a technique capable of attaching the surfactant to the surface of the porous substrate, and a solution containing the surfactant is applied to the porous substrate. What is necessary is just to apply
- the porous substrate may be immersed in the solution containing the surfactant while stirring the solution at room temperature or high temperature (for example, 40 to 80 ° C.), and the immersion time is not particularly limited, but may be, for example, 1 to 7 days. is there.
- the starting point of LDH crystal growth can be a chemical species that provides cations that can be a component of the layered double hydroxide.
- a preferred example of such a cation is Al 3+ .
- the starting material is preferably at least one aluminum compound selected from the group consisting of aluminum oxides, hydroxides, oxyhydroxides, and hydroxy complexes. Therefore, the starting material that can provide such a starting point may be uniformly attached to the surface of the porous member by an appropriate method according to the type of the starting material.
- the starting material can be attached by applying a sol containing an aluminum compound to the porous member.
- a sol containing an aluminum compound examples include boehmite (AlOOH), aluminum hydroxide (Al (OH) 3 ), and amorphous alumina, with boehmite being most preferred.
- the application of the sol containing the aluminum compound is preferably performed by spin coating because it can be applied uniformly.
- the spin coating conditions are not particularly limited.
- the spin coating may be performed at a rotational speed of 1000 to 10000 rpm for about 60 to 300 seconds including dripping and drying.
- the starting material is adhered by subjecting the porous substrate to hydrothermal treatment in an aqueous solution containing at least aluminum to form an aluminum compound on the surface of the porous substrate.
- the aluminum compound formed on the surface of the porous substrate is preferably Al (OH) 3 .
- LDH films on porous substrates tend to produce crystalline and / or amorphous Al (OH) 3 in the initial stage of growth. Can grow. Therefore, after the Al (OH) 3 is uniformly attached to the surface of the porous substrate by hydrothermal treatment in advance, the step (c) that also involves hydrothermal treatment is performed, The LDH film can be uniformly formed without unevenness.
- the step (b) and the subsequent step (c) may be performed continuously in the same sealed container, or the step (b) and the subsequent step (c) are performed separately in this order. May be.
- the raw material aqueous solution that is, an aqueous solution containing an LDH constituent element
- the hydrothermal treatment in the step (b) is compared with 50 to 70 ° C. in an acidic or neutral pH range (preferably pH 5.5 to 7.0) in a sealed container (preferably autoclave). By performing in a low temperature range, it is possible to promote nucleation of Al (OH) 3 instead of LDH.
- step (c) at (preferably more than pH 7.0).
- step (b) and the step (c) are separately performed in this order, it is preferable to use different raw material aqueous solutions in the step (b) and the step (c).
- step (b) it is preferable to nucleate Al (OH) 3 using a raw material aqueous solution mainly containing an Al source (preferably not containing other metal elements).
- the hydrothermal treatment in the step (b) may be carried out at 50 to 120 ° C. in a closed container (preferably an autoclave) different from the step (c).
- the raw material aqueous solution mainly containing an Al source include an aqueous solution containing aluminum nitrate and urea and not containing a magnesium compound (for example, magnesium nitrate).
- a raw material aqueous solution not containing Mg precipitation of LDH can be avoided and nucleation of Al (OH) 3 can be promoted.
- the starting material is adhered by depositing aluminum on the surface of the porous substrate and then converting the aluminum into an aluminum compound by hydrothermal treatment in an aqueous solution.
- This aluminum compound is preferably Al (OH) 3 .
- Al (OH) 3 the growth of LDH can be promoted using this as a nucleus. Therefore, after the Al (OH) 3 is uniformly formed on the surface of the porous base material by hydrothermal treatment, the same process (c) accompanied by hydrothermal treatment is carried out. A densified LDH film can be uniformly formed without unevenness.
- Aluminum may be deposited by physical vapor deposition or chemical vapor deposition, but physical vapor deposition such as vacuum vapor deposition is preferred.
- the aqueous solution used for the hydrothermal treatment for aluminum conversion should just be a composition which can react with Al already provided by vapor deposition and can produce
- the starting point for crystal growth can be LDH.
- the growth of LDH can be promoted starting from the nucleus of LDH. Therefore, after the LDH nuclei are uniformly attached to the surface of the porous base material, the subsequent step (c) is performed to unevenly disperse the highly densified LDH film on the surface of the porous base material. And can be formed uniformly.
- the starting material can be attached by applying a sol containing LDH to the surface of the porous member.
- the sol containing LDH may be prepared by dispersing LDH in a solvent such as water, and is not particularly limited.
- the application is preferably performed by spin coating.
- Spin coating is preferred because it can be applied very uniformly.
- the spin coating conditions are not particularly limited.
- the spin coating may be performed at a rotational speed of 1000 to 10000 rpm for about 60 to 300 seconds including dripping and drying.
- the deposition of the starting material is performed by depositing aluminum (deposited) in an aqueous solution containing a constituent element of LDH other than aluminum after depositing aluminum on the surface of the porous substrate. It can be performed by converting to LDH by hydrothermal treatment.
- Aluminum may be deposited by physical vapor deposition or chemical vapor deposition, but physical vapor deposition such as vacuum vapor deposition is preferred.
- the raw material aqueous solution used for the hydrothermal treatment for the conversion of aluminum may be performed using an aqueous solution containing a component other than Al already provided by vapor deposition.
- a preferable example of such a raw material aqueous solution is a raw material aqueous solution mainly containing a Mg source, and more preferably, an aqueous solution containing magnesium nitrate and urea and not containing an aluminum compound (aluminum nitrate).
- a Mg source By including the Mg source, the nuclei of LDH can be formed together with Al already provided by vapor deposition.
- a hydrothermal treatment is performed on a porous substrate (a starting material can be attached if desired) in a raw material aqueous solution containing a constituent element of LDH to form an LDH film on the surface of the porous substrate.
- a preferable raw material aqueous solution contains magnesium ions (Mg 2+ ) and aluminum ions (Al 3+ ) at a predetermined total concentration, and contains urea. Due to the presence of urea, ammonia is generated in the solution by utilizing hydrolysis of urea, so that the pH value rises (for example, more than pH 7.0, preferably more than 7.0 and less than 8.5) and coexists. LDH can be obtained when metal ions form hydroxides.
- the total concentration (Mg 2+ + Al 3+ ) of magnesium ions and aluminum ions contained in the raw material aqueous solution is preferably 0.20 to 0.40 mol / L, more preferably 0.22 to 0.38 mol / L, still more preferably The amount is 0.24 to 0.36 mol / L, particularly preferably 0.26 to 0.34 mol / L.
- concentration is within such a range, nucleation and crystal growth can proceed in a balanced manner, and an LDH film excellent not only in orientation but also in denseness can be obtained. That is, when the total concentration of magnesium ions and aluminum ions is low, crystal growth becomes dominant compared to nucleation, and the number of particles decreases and particle size increases. It is considered that the generation becomes dominant, the number of particles increases, and the particle size decreases.
- magnesium nitrate and aluminum nitrate are dissolved in the raw material aqueous solution, so that the raw material aqueous solution contains nitrate ions in addition to magnesium ions and aluminum ions.
- the molar ratio of urea to nitrate ions (NO 3 ⁇ ) (urea / NO 3 ⁇ ) in the raw material aqueous solution is preferably 2 to 6, and more preferably 4 to 5.
- the porous substrate may be immersed in the raw material aqueous solution in a desired direction (for example, horizontally or vertically).
- a desired direction for example, horizontally or vertically.
- the porous substrate may be suspended, floated, or disposed so as to be in contact with the bottom of the container.
- the porous substrate is suspended from the bottom of the container in the raw material aqueous solution.
- the material may be fixed.
- a jig that can set the porous substrate vertically on the bottom of the container may be placed.
- LDH is substantially perpendicular to or close to the porous substrate (that is, the LDH plate-like particles have their plate surfaces intersecting the surface (substrate surface) of the porous substrate substantially perpendicularly or obliquely. It is preferable to adopt a configuration or arrangement in which growth is performed in such a direction.
- the porous substrate is subjected to hydrothermal treatment to form an LDH film on the surface of the porous substrate.
- This hydrothermal treatment is preferably carried out in a sealed container (preferably an autoclave) at 60 to 150 ° C., more preferably 65 to 120 ° C., further preferably 65 to 100 ° C., particularly preferably 70 to 90 ° C.
- the upper limit temperature of the hydrothermal treatment may be selected so that the porous substrate (for example, the polymer substrate) is not deformed by heat.
- the rate of temperature increase during the hydrothermal treatment is not particularly limited, and may be, for example, 10 to 200 ° C./h, preferably 100 to 200 ° C./h, more preferably 100 to 150 ° C./h.
- the hydrothermal treatment time may be appropriately determined according to the target density and thickness of the LDH film.
- the porous substrate After the hydrothermal treatment, it is preferable to take out the porous substrate from the sealed container and wash it with ion-exchanged water.
- the LDH film produced as described above is one in which LDH plate-like particles are highly densified and oriented in a substantially vertical direction advantageous for conduction. That is, the LDH film typically does not have water permeability (desirably water permeability and air permeability) due to high density.
- the LDH constituting the LDH film is composed of an aggregate of a plurality of plate-like particles, and the plurality of plate-like particles cross their surfaces substantially perpendicularly or obliquely with the surface of the porous substrate. Typically oriented in the direction.
- an improvement in power generation performance can be expected, and a secondary battery for a zinc-air battery using an electrolyte that has not been conventionally applicable It is expected to be applied to new separators such as zinc dendrite progress barriers and carbon dioxide intrusion separators, which have become major barriers to chemical conversion. Similarly, it is expected to be applied to a nickel-zinc battery in which the progress of zinc dendrite is a major barrier to practical use.
- the LDH film obtained by the above production method can be formed on both surfaces of the porous substrate. For this reason, in order to make the LDH film suitable for use as a separator, the LDH film on one side of the porous substrate is mechanically scraped after film formation, or the LDH film is formed on one side during film formation. It is desirable to take measures that prevent film formation.
- samples A1 to A10 were produced as follows as LDH-containing composite material samples in which a layered double hydroxide (LDH) film was formed on a porous substrate.
- LDH layered double hydroxide
- the porosity of the surface of the porous substrate was measured by a technique using image processing, and it was 24.6%.
- the porosity is measured by 1) observing the surface microstructure with an accelerating voltage of 10 to 20 kV using a scanning electron microscope (SEM, JSM-6610LV, manufactured by JEOL Co., Ltd.). SEM) image (magnification of 10,000 times or more) is obtained, 2) a grayscale SEM image is read using image analysis software such as Photoshop (manufactured by Adobe), etc.
- the average pore diameter of the porous substrate was measured, it was about 0.1 ⁇ m.
- the average pore diameter was measured by measuring the longest distance of the pores based on an electron microscope (SEM) image of the surface of the porous substrate.
- the magnification of the electron microscope (SEM) image used for this measurement is 20000 times, and all the obtained pore diameters are arranged in order of size, and the top 15 points and the bottom 15 points from the average value, and 30 points per visual field in total.
- the average value for two visual fields was calculated to obtain the average pore diameter.
- the length measurement function of SEM software was used.
- magnesium nitrate hexahydrate (Mg (NO 3) 2 ⁇ 6H 2 O, manufactured by Kanto Chemical Co., Inc.), aluminum nitrate nonahydrate (Al (NO 3) 3 ⁇ 9H 2 O, manufactured by Kanto Chemical Co., Ltd.) and urea ((NH 2 ) 2 CO, manufactured by Sigma-Aldrich) were prepared.
- Mg (NO 3) 2 ⁇ 6H 2 O manufactured by Kanto Chemical Co., Inc.
- Al (NO 3) 3 ⁇ 9H 2 O manufactured by Kanto Chemical Co., Ltd.
- urea ((NH 2 ) 2 CO, manufactured by Sigma-Aldrich)
- ion exchange water was added to make a total volume of 75 ml.
- LDH layered double hydroxide
- a membrane sample a dense layer of layered double hydroxide (hereinafter referred to as a membrane sample). ) was obtained on a substrate.
- the thickness of the obtained film sample was about 1.0 to 2.0 ⁇ m.
- samples A1 to A10 were obtained as LDH-containing composite material samples (hereinafter referred to as composite material samples).
- composite material samples the LDH film was formed on both surfaces of the porous substrate, the LDH film on one surface of the porous substrate was mechanically scraped to give the composite material a form as a separator.
- Example A2 Identification of a film sample Using an X-ray diffractometer (RINT TTR III, manufactured by Rigaku Corporation), the crystal phase of the film sample was measured under the measurement conditions of voltage: 50 kV, current value: 300 mA, measurement range: 10 to 70 °. To obtain an XRD profile. About the obtained XRD profile, JCPDS card NO. Identification was performed using a diffraction peak of a layered double hydroxide (hydrotalcite compound) described in 35-0964. As a result, it was confirmed that all of the film samples A1 to A10 were layered double hydroxides (LDH, hydrotalcite compounds).
- LDH layered double hydroxides
- Example A3 He Permeation Measurement A He permeation test was performed as follows to evaluate the denseness of the membrane samples A1 to A10 from the viewpoint of He permeability.
- the He permeability measurement system 10 shown in FIGS. 1A and 1B was constructed.
- He gas from a gas cylinder filled with He gas is supplied to a sample holder 16 via a pressure gauge 12 and a flow meter 14 (digital flow meter), and the denseness held in the sample holder 16 is maintained.
- the membrane 18 is configured to pass through one surface of the membrane 18 and to be discharged.
- the sample holder 16 has a structure including a gas supply port 16a, a sealed space 16b, and a gas discharge port 16c, and was assembled as follows.
- the adhesive 22 was applied along the outer periphery of the dense film 18 and attached to a jig 24 (made of ABS resin) having an opening at the center.
- Sealing members 26a and 26b are provided with sealing members 26a and 26b on the upper and lower ends of the jig 24, and support members 28a and 28b (made of PTFE) provided with openings made of flanges from the outside of the sealing members 26a and 26b.
- the sealed space 16b was defined by the dense film 18, the jig 24, the sealing member 26a, and the support member 28a.
- the dense film 18 is in the form of a composite material formed on the porous substrate 20, but is arranged so that the dense film 18 side faces the gas supply port 16a.
- the support members 28a and 28b were tightly fastened to each other by fastening means 30 using screws so that He gas does not leak from portions other than the gas discharge port 16c.
- a gas supply pipe 34 was connected to the gas supply port 16 a of the sample holder 16 assembled in this way via a joint 32.
- He gas was supplied to the He permeability measurement system 10 through the gas supply pipe 34 and permeated through the dense film 18 held in the sample holder 16.
- the gas supply pressure and the flow rate were monitored by the pressure gauge 12 and the flow meter 14.
- the He permeability was calculated. The calculation of the He permeability is based on the permeation amount F (cm 3 / min) of He gas per unit time, the differential pressure P (atm) applied to the dense film during He gas permeation, and the membrane area S (cm 2 ) and calculated by the formula of F / (P ⁇ S).
- the permeation amount F (cm 3 / min) of He gas was directly read from the flow meter 14.
- the differential pressure P was a gauge pressure read from the pressure gauge 12.
- the He gas was supplied so that the differential pressure P was in the range of 0.05 to 0.90 atm. The obtained results were as shown in Table 1 and FIG.
- Example A4 Zn Permeation Test
- a Zn permeation test was performed as follows. First, the Zn transmission measuring device 40 shown in FIGS. 2A and 2B was constructed.
- the Zn transmission measuring device 40 includes a flanged opening tube (manufactured by PTFE) in which a flange 62a is integrated with a first tank 44 formed of an L-shaped opening tube, and a second formed of an L-shaped tube.
- a flanged opening tube (made of PTFE) in which the flange 62b is integrated with the tank 46 is disposed so that the flanges 62a and 62b face each other, and the sample holder 42 is disposed therebetween, and the dense film held by the sample holder 42 Zn was allowed to pass through from one surface to the other.
- the assembly of the sample holder 42 and its attachment to the apparatus 40 were performed as follows. First, an adhesive 56 was applied along the outer periphery of the dense film 52 and attached to a jig 58 (made of ABS resin) having an opening at the center. As shown in FIG. 1A, silicone rubber packing is disposed on both sides of the jig 58 as sealing members 60a and 60b. Further, from the outside of the sealing members 60a and 60b, a flange 62a of a pair of flanged open tubes. 62b.
- the dense film 52 is in the form of a composite material formed on the porous substrate 54, but the dense film 52 side (the first aqueous solution 48 containing Zn is injected) is the first tank 44. It was arranged to face. The flanges 62a and 62b were fastened to each other by fastening means 64 using screws so that no liquid leakage occurred between them.
- a 9 mol / L aqueous solution of KOH in which 2.5 mol / L of Al (OH) 3 and 0.5 mol / L of ZnO were dissolved was prepared as the first aqueous solution 48 to be put in the first tank 44.
- Zn concentration C 1 (mol / L) of the first aqueous solution was measured by ICP emission spectroscopy, it was a value shown in Table 1.
- a 9 mol / L KOH aqueous solution in which 2.5 mol / L of Al (OH) 3 was dissolved was prepared without dissolving ZnO.
- the first aqueous solution 48 and the second aqueous solution 50 are injected into the first tank 44 and the second tank 46, respectively, and the densely held by the sample holder 42 is obtained.
- Zn was permeated through the film 52. In this state, Zn permeation was performed at time t shown in Table 1, and then the liquid volume V 2 (ml) of the second aqueous solution was measured, and the Zn concentration C 2 (mol / L) of the second aqueous solution 50 was determined. It was measured by ICP emission spectroscopy. The Zn permeation ratio was calculated using the obtained value.
- the Zn permeation ratio includes the Zn concentration C 1 (mol / L) of the first aqueous solution before the start of Zn permeation, the liquid volume V 1 (ml) of the first aqueous solution before the start of Zn permeation, and the second concentration after the end of Zn permeation.
- Examples B1 to B5 The example shown below is not an example of evaluating the He permeability and the Zn transmission ratio, but is a reference example showing that an LDH dense film can be formed on various porous substrates.
- Example B1 (1) Production of porous substrate ⁇ Samples B1 to B3> Boehmite (manufactured by Sasol, DISPAL 18N4-80), methylcellulose, and ion-exchanged water were weighed so that the mass ratio of (boehmite) :( methylcellulose) :( ion-exchanged water) was 10: 1: 5. Kneaded. The obtained kneaded product was subjected to extrusion molding using a hand press and molded into a size of 2.5 cm ⁇ 10 cm ⁇ thickness 0.5 cm. The obtained molded body was dried at 80 ° C. for 12 hours and then fired at the temperature shown in Table 2 for 3 hours to obtain an alumina porous substrate. After firing, the alumina porous substrate was processed into a size of 2 cm ⁇ 2 cm ⁇ 0.3 cm.
- the obtained kneaded product was subjected to extrusion molding using a hand press and molded into a size of 2.5 cm ⁇ 10 cm ⁇ thickness 0.5 cm.
- the obtained molded body was dried at 80 ° C. for 12 hours and then fired at the temperature shown in Table 2 for 3 hours to obtain a zirconia porous substrate. After firing, the zirconia porous substrate was processed into a size of 2 cm ⁇ 2 cm ⁇ 0.3 cm.
- the porosity of the surface of the porous substrate was measured by a technique using image processing, and as shown in Table 2.
- the porosity is measured by 1) field emission scanning electron microscope (FE-SEM) for sample B1 and scanning electron microscope (SEM, JSM-6610LV) for samples B2 to B5. , Manufactured by JEOL Co., Ltd., and observed with a predetermined acceleration voltage (1 kV for sample B1, 10 to 20 kV for samples B2 to B5), and an electron microscope image of the porous substrate surface (magnification of 10,000 times or more, for sample B1) 2) Read a grayscale electron microscope image using image analysis software such as Photoshop (manufactured by Adobe), etc.
- image analysis software such as Photoshop (manufactured by Adobe), etc.
- the average pore diameter of the porous substrate was measured, it was as shown in Table 2.
- the average pore diameter was measured by measuring the longest distance of pores based on an electron microscope (FE-SEM or SEM) image of the surface of the porous substrate.
- the magnification of the electron microscope (FE-SEM or SEM) image used for this measurement is 100,000 times for the sample B1, and 20000 times for the samples B2 to B5.
- the average pore diameter was obtained by calculating the average value for two visual fields at the top 15 points and the lower 15 points from the values, and 30 points per visual field.
- the length measurement function of FE-SEM or SEM software was used.
- magnesium nitrate hexahydrate (Mg (NO 3) 2 ⁇ 6H 2 O, manufactured by Kanto Chemical Co., Inc.), aluminum nitrate nonahydrate (Al (NO 3) 3 ⁇ 9H 2 O, manufactured by Kanto Chemical Co., Ltd.) and urea ((NH 2 ) 2 CO, manufactured by Sigma-Aldrich) were prepared.
- Mg (NO 3) 2 ⁇ 6H 2 O manufactured by Kanto Chemical Co., Inc.
- Al (NO 3) 3 ⁇ 9H 2 O manufactured by Kanto Chemical Co., Ltd.
- urea ((NH 2 ) 2 CO, manufactured by Sigma-Aldrich)
- ion exchange water was added to make a total volume of 75 ml.
- the substrate is taken out from the sealed container, washed with ion-exchanged water, dried at 70 ° C. for 10 hours, and a dense layer of layered double hydroxide (hereinafter referred to as LDH) (hereinafter referred to as membrane sample B1).
- LDH layered double hydroxide
- membrane sample B1 to B5 were obtained on the substrate.
- the thickness of the obtained film sample was about 1.5 ⁇ m.
- composite material samples B1 to B5 were obtained.
- composite material samples B1 to B5 were obtained.
- composite material samples B1 to B5 were obtained.
- the LDH film was formed on both surfaces of the porous substrate, the LDH film on one surface of the porous substrate was mechanically scraped to give the composite material a form as a separator.
- Example B2 Identification of a film sample Using an X-ray diffractometer (RINT TTR III manufactured by Rigaku Corporation), the crystal phase of the film sample B2 was measured under the measurement conditions of voltage: 50 kV, current value: 300 mA, measurement range: 10 to 70 °. As a result of measurement, the XRD profile shown in FIG. 6 was obtained. About the obtained XRD profile, JCPDS card NO. It was identified using the diffraction peak of the layered double hydroxide (hydrotalcite compound) described in 35-0964. As a result, it was confirmed that the film sample B2 was a layered double hydroxide (LDH, hydrotalcite compound). In the XRD profile shown in FIG.
- a peak (a peak marked with a circle in FIG. 6) due to alumina constituting the porous substrate on which the film sample B2 is formed is also observed. Yes.
- the film samples B1 and B3 to B5 were similarly confirmed to be layered double hydroxides (LDH, hydrotalcite compounds).
- Example B3 Observation of microstructure The surface microstructure of the film sample B2 was observed with a scanning electron microscope (SEM, JSM-6610LV, manufactured by JEOL) at an acceleration voltage of 10 to 20 kV.
- SEM scanning electron microscope
- JSM-6610LV manufactured by JEOL
- FIG. 7 shows an SEM image (secondary electron image) of the surface microstructure of the obtained film sample B2.
- the cross section of the composite material sample B2 was polished by CP polishing to form a polished cross section, and the microstructure of the polished cross section was observed with a scanning electron microscope (SEM) at an acceleration voltage of 10 to 20 kV.
- SEM scanning electron microscope
- Example B4 Measurement of porosity
- the porosity of the surface of the membrane of the membrane sample B2 was measured by a technique using image processing. The porosity is measured by 1) observing the surface microstructure with a scanning electron microscope (SEM, JSM-6610LV, manufactured by JEOL) at an acceleration voltage of 10 to 20 kV, and observing an electron microscope (SEM) on the surface of the film.
- SEM scanning electron microscope
- the porosity of the polished cross section was also measured for the film sample B2.
- the porosity of this polished cross section is also measured by the above-described film surface except that an electron microscope (SEM) image (magnification of 10,000 times or more) of the cross-section polished surface in the thickness direction of the film was obtained according to the procedure shown in Example B3. This was carried out in the same manner as the porosity.
- This porosity measurement was performed on the membrane portion of the membrane sample cross section.
- the porosity calculated from the cross-sectional polished surface of the film sample B2 is 3.5% on average (average value of the three cross-sectional polished surfaces), and a very high-density film is formed on the porous substrate. It has been confirmed.
- Example B5 Denseness determination test (reference) In order to confirm that the membrane samples B1 to B5 have a denseness that does not have water permeability, a denseness determination test was performed as follows. First, as shown in FIG. 9A, an opening of 0.5 cm ⁇ 0.5 cm square is formed in the center on the film sample side of the composite material sample 120 (cut out to 1 cm ⁇ 1 cm square) obtained in Example B1. Silicone rubber 122 provided with 22a was bonded, and the resulting laminate was bonded between two acrylic containers 124 and 126. The bottom of the acrylic container 124 disposed on the silicon rubber 122 side is pulled out, whereby the silicon rubber 122 is bonded to the acrylic container 124 with the opening 122a open.
- the acrylic container 126 disposed on the porous substrate side of the composite material sample 120 has a bottom, and ion-exchanged water 128 is contained in the container 126.
- Al and / or Mg may be dissolved in the ion exchange water. That is, by assembling the components upside down after assembly, the constituent members are arranged so that the ion exchange water 128 is in contact with the porous substrate side of the composite material sample 120. After assembling these components, the total weight was measured. Needless to say, the container 126 has a closed vent hole (not shown) and is opened after being turned upside down. As shown in FIG. 9B, the assembly was placed upside down and held at 25 ° C. for 1 week, after which the total weight was measured again.
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Abstract
Description
本発明は、水酸化物イオン伝導緻密膜に関する。水酸化物イオン伝導緻密膜は、好ましくは層状複水酸化物緻密膜(LDH緻密膜)であるが、これに限定されず、水酸化物イオン伝導性を有するあらゆる緻密膜であってよく、例えば水酸化物イオン伝導性を有する無機材料及び/又は有機材料を含んでなる膜であることができる。いずれにしても、水酸化物イオン伝導緻密膜は透水性を有しない程に緻密な膜であることが望まれる。この緻密膜は水酸化物イオン伝導性を有するが透水性を有しないことで、電池用セパレータとしての機能を呈することができる。前述したとおり、電池用固体電解質セパレータとしてLDHの適用を考えた場合、バルク形態のLDH緻密体では高抵抗であるとの問題があったが、緻密膜の形態とすることで厚みを薄くして低抵抗化を図ることができる。すなわち、緻密膜は、金属空気電池(例えば亜鉛空気電池)及びその他各種亜鉛二次電池(例えばニッケル亜鉛電池)等の各種電池用途に適用可能な固体電解質セパレータとして、極めて有用な材料となりうる。もっとも、局所的且つ/又は偶発的に透水性を有する欠陥が緻密膜に存在する場合には、当該欠陥を適当な補修剤(例えばエポキシ樹脂等)で埋めて補修することで水不透性を確保してもよく、そのような補修剤は必ずしも水酸化物イオン伝導性を有する必要はない。
緻密膜(好ましくはLDH膜)は多孔質基材の少なくとも一方の表面に設けられるのが好ましい。すなわち、本発明の好ましい態様によれば、多孔質基材と、該多孔質基材の少なくとも一方の表面に設けられる上記水酸化物イオン伝導緻密膜とを備えた、複合材料が提供される。ここで、多孔質基材の表面とは、多孔質基材の概形を板として巨視的に見た場合の板面の最表面を主として指すが、多孔質基材中における微視的に見て板面最表面の近傍に存在する孔の表面をも付随的に包含しうるのはいうまでもない。
本発明によるLDH膜及びLDH含有複合材料は、(a)多孔質基材を用意し、(b)所望により、この多孔質基材に、LDHの結晶成長の起点を与えうる起点物質を均一に付着させ、(c)多孔質基材に水熱処理を施してLDH膜を形成させることにより、好ましく製造することができる。
多孔質基材は、前述したとおりであり、セラミックス材料、金属材料、及び高分子材料からなる群から選択される少なくとも1種で構成されるのが好ましい。多孔質基材は、セラミックス材料で構成されるのがより好ましい。この場合、セラミックス材料の好ましい例としては、アルミナ、ジルコニア、チタニア、マグネシア、スピネル、カルシア、コージライト、ゼオライト、ムライト、フェライト、酸化亜鉛、炭化ケイ素、及びそれらの任意の組合せが挙げられ、より好ましくは、アルミナ、ジルコニア、チタニア、及びそれらの任意の組合せであり、特に好ましくはアルミナ、ジルコニア(例えばイットリア安定化ジルコニア(YSZ))、及びその組合せである。これらの多孔質セラミックスを用いるとLDH膜の緻密性を向上しやすい傾向がある。セラミックス材料製の多孔質基材を用いる場合、超音波洗浄、イオン交換水での洗浄等を多孔質基材に施すのが好ましい。
所望により、多孔質基材に、LDHの結晶成長の起点を与えうる起点物質を均一に付着させてもよい。このように起点物質を多孔質基材の表面に均一に付着させた後に、後続の工程(c)を行うことで、多孔質基材の表面に、高度に緻密化されたLDH膜をムラなく均一に形成することができる。このような起点の好ましい例としては、LDHの層間に入りうる陰イオンを与える化学種、LDHの構成要素となりうる陽イオンを与える化学種、又はLDHが挙げられる。
LDHの結晶成長の起点は、LDHの層間に入りうる陰イオンを与える化学種であることができる。このような陰イオンの例としては、CO3 2-、OH-、SO3 -、SO3 2-、SO4 2-、NO3 -、Cl-、Br-、及びこれらの任意の組合せが挙げられる。したがって、このような起点を与えうる起点物質を、起点物質の種類に応じた適切な手法で均一に多孔質基材の表面に付着させればよい。表面に陰イオンを与える化学種が付与されることで、Mg2+、Al3+等の金属陽イオンが多孔質基材の表面に吸着してLDHの核が生成しうる。このため、後続の工程(c)を行うことで、多孔質基材の表面に、高度に緻密化されたLDH膜をムラなく均一に形成することができる。
LDHの結晶成長の起点は、層状複水酸化物の構成要素となりうる陽イオンを与える化学種であることができる。このような陽イオンの好ましい例としては、Al3+が挙げられる。この場合、起点物質が、アルミニウムの酸化物、水酸化物、オキシ水酸化物及びヒドロキシ錯体からなる群から選択される少なくとも1種のアルミニウム化合物であるのが好ましい。したがって、このような起点を与えうる起点物質を起点物質の種類に応じた適切な手法で均一に多孔質部材の表面に付着させればよい。表面に陽イオンを与える化学種が付与されることで、LDHの層間に入りうる陰イオンが多孔質基材の表面に吸着してLDHの核が生成しうる。このため、後続の工程(c)を行うことで、多孔質基材の表面に、高度に緻密化されたLDH膜をムラなく均一に形成することができる。
結晶成長の起点は、LDHであることができる。この場合、LDHの核を起点としてLDHの成長を促すことができる。そこで、このLDHの核を多孔質基材の表面に均一に付着させた後に、後続の工程(c)を行うことで、多孔質基材の表面に、高度に緻密化されたLDH膜をムラなく均一に形成することができる。
LDHの構成元素を含む原料水溶液中で、多孔質基材(所望により起点物質が付着されうる)に水熱処理を施して、LDH膜を多孔質基材の表面に形成させる。好ましい原料水溶液は、マグネシウムイオン(Mg2+)及びアルミニウムイオン(Al3+)を所定の合計濃度で含み、かつ、尿素を含んでなる。尿素が存在することで尿素の加水分解を利用してアンモニアが溶液中に発生することによりpH値が上昇し(例えばpH7.0超、好ましくは7.0を超え8.5以下)、共存する金属イオンが水酸化物を形成することによりLDHを得ることができる。また、加水分解に二酸化炭素の発生を伴うため、陰イオンが炭酸イオン型のLDHを得ることができる。原料水溶液に含まれるマグネシウムイオン及びアルミニウムイオンの合計濃度(Mg2++Al3+)は0.20~0.40mol/Lが好ましく、より好ましくは0.22~0.38mol/Lであり、さらに好ましくは0.24~0.36mol/L、特に好ましくは0.26~0.34mol/Lである。このような範囲内の濃度であると核生成と結晶成長をバランスよく進行させることができ、配向性のみならず緻密性にも優れたLDH膜を得ることが可能となる。すなわち、マグネシウムイオン及びアルミニウムイオンの合計濃度が低いと核生成に比べて結晶成長が支配的となり、粒子数が減少して粒子サイズが増大する一方、この合計濃度が高いと結晶成長に比べて核生成が支配的となり、粒子数が増大して粒子サイズが減少するものと考えられる。
本例では、多孔質基材上に層状複水酸化物(LDH)膜を形成したLDH含有複合材料試料として試料A1~A10を以下のようにして作製した。
ベーマイト(サソール社製、DISPAL 18N4-80)、メチルセルロース、及びイオン交換水を、(ベーマイト):(メチルセルロース):(イオン交換水)の質量比が10:1:5となるように秤量した後、混練した。得られた混練物を、ハンドプレスを用いた押出成形に付し、2.5cm×10cm×厚さ0.5cmの大きさに成形した。得られた成形体を80℃で12時間乾燥した後、1150℃で3時間焼成して、アルミナ製多孔質基材を得た。
得られた多孔質基材をアセトン中で5分間超音波洗浄し、エタノール中で2分間超音波洗浄、その後、イオン交換水中で1分間超音波洗浄した。
試料A1~A6についてのみ、以下の手順により多孔質基材に対してポリスチレンスピンコート及びスルホン化を行った。すなわち、ポリスチレン基板0.6gをキシレン溶液10mlに溶かして、ポリスチレン濃度0.06g/mlのスピンコート液を作製した。得られたスピンコート液0.1mlを多孔質基材上に滴下し、回転数8000rpmでスピンコートにより塗布した。このスピンコートは、滴下と乾燥を含めて200秒間行った。スピンコート液を塗布した多孔質基材を95%硫酸に25℃で4日間浸漬してスルホン化した。
原料として、硝酸マグネシウム六水和物(Mg(NO3)2・6H2O、関東化学株式会社製)、硝酸アルミニウム九水和物(Al(NO3)3・9H2O、関東化学株式会社製)、及び尿素((NH2)2CO、シグマアルドリッチ製)を用意した。カチオン比(Mg2+/Al3+)が2となり且つ全金属イオンモル濃度(Mg2++Al3+)が0.320mol/Lとなるように、硝酸マグネシウム六水和物と硝酸アルミニウム九水和物を秤量してビーカーに入れ、そこにイオン交換水を加えて全量を75mlとした。得られた溶液を攪拌した後、溶液中に尿素/NO3 -=4の割合で秤量した尿素を加え、更に攪拌して原料水溶液を得た。
テフロン(登録商標)製密閉容器(内容量100ml、外側がステンレス製ジャケット)に上記(4)で作製した原料水溶液と上記(3)でスルホン化した多孔質基材(試料A1~A6)又は上記(2)で洗浄した多孔質基材(試料A7~A10)を共に封入した。このとき、基材はテフロン(登録商標)製密閉容器の底から浮かせて固定し、基材両面に溶液が接するように水平に設置した。その後、水熱温度70~75℃で168~504時間水熱処理を施すことにより基材表面に層状複水酸化物配向膜の形成を行った。このとき、水熱処理の条件を適宜変更することにより、様々な緻密性を有する10種類の配向膜を作製した。所定時間の経過後、基材を密閉容器から取り出し、イオン交換水で洗浄し、70℃で10時間乾燥させて、層状複水酸化物(以下、LDHという)の緻密膜(以下、膜試料という)を基材上に得た。得られた膜試料の厚さは約1.0~2.0μmであった。こうして、LDH含有複合材料試料(以下、複合材料試料という)として試料A1~A10を得た。なお、LDH膜は多孔質基材の両面に形成されていたが、セパレータとしての形態を複合材料に付与するため、多孔質基材の片面のLDH膜を機械的に削り取った。
X線回折装置(リガク社製 RINT TTR III)にて、電圧:50kV、電流値:300mA、測定範囲:10~70°の測定条件で、膜試料の結晶相を測定してXRDプロファイルを得る。得られたXRDプロファイルについて、JCPDSカードNO.35-0964に記載される層状複水酸化物(ハイドロタルサイト類化合物)の回折ピークを用いて同定を行った。その結果、膜試料A1~A10のいずれも層状複水酸化物(LDH、ハイドロタルサイト類化合物)であることが確認された。
He透過性の観点から膜試料A1~A10の緻密性を評価すべくHe透過試験を以下のとおり行った。まず、図1A及び図1Bに示されるHe透過度測定系10を構築した。He透過度測定系10は、Heガスを充填したガスボンベからのHeガスが圧力計12及び流量計14(デジタルフローメーター)を介して試料ホルダ16に供給され、この試料ホルダ16に保持された緻密膜18の一方の面から他方の面に透過させて排出させるように構成した。
Zn透過性の観点から膜試料A1~A10の緻密性を評価すべく、Zn透過試験を以下のとおり行った。まず、図2A及び図2Bに示されるZn透過測定装置40を構築した。Zn透過測定装置40は、L字状の開口管で構成される第一槽44にフランジ62aが一体化されたフランジ付き開口管(PTFE製)と、L字状の管で構成される第二槽46にフランジ62bが一体化されたフランジ付き開口管(PTFE製)とをフランジ62a,62bが対向するように配置し、その間に試料ホルダ42を配置し、試料ホルダ42に保持された緻密膜の一方の面から他方の面にZnが透過可能な構成とした。
以下に示される例はHe透過度及びZn透過割合の評価を行った例ではないが、各種多孔質基材上にLDH緻密膜を形成できることを示す参考例である。
(1)多孔質基材の作製
<試料B1~B3>
ベーマイト(サソール社製、DISPAL 18N4-80)、メチルセルロース、及びイオン交換水を、(ベーマイト):(メチルセルロース):(イオン交換水)の質量比が10:1:5となるように秤量した後、混練した。得られた混練物を、ハンドプレスを用いた押出成形に付し、2.5cm×10cm×厚さ0.5cmの大きさに成形した。得られた成形体を80℃で12時間乾燥した後、表2に示される温度で3時間焼成して、アルミナ製多孔質基材を得た。焼成後、アルミナ製多孔質基材を2cm×2cm×0.3cmの大きさに加工した。
ジルコニア(東ソー社製、TZ-3YS(試料B4の場合)又はTZ-8YS(試料B5の場合))、メチルセルロース、及びイオン交換水を、(ジルコニア):(メチルセルロース):(イオン交換水)の質量比が10:1:5となるように秤量した後、混練した。得られた混練物を、ハンドプレスを用いた押出成形に付し、2.5cm×10cm×厚さ0.5cmの大きさに成形した。得られた成形体を80℃で12時間乾燥した後、表2に示される温度で3時間焼成して、ジルコニア製多孔質基材を得た。焼成後、ジルコニア製多孔質基材を2cm×2cm×0.3cmの大きさに加工した。
得られた多孔質基材をアセトン中で5分間超音波洗浄し、エタノール中で2分間超音波洗浄、その後、イオン交換水中で1分間超音波洗浄した。
原料として、硝酸マグネシウム六水和物(Mg(NO3)2・6H2O、関東化学株式会社製)、硝酸アルミニウム九水和物(Al(NO3)3・9H2O、関東化学株式会社製)、及び尿素((NH2)2CO、シグマアルドリッチ製)を用意した。カチオン比(Mg2+/Al3+)が2となり且つ全金属イオンモル濃度(Mg2++Al3+)が0.320mol/Lとなるように、硝酸マグネシウム六水和物と硝酸アルミニウム九水和物を秤量してビーカーに入れ、そこにイオン交換水を加えて全量を75mlとした。得られた溶液を攪拌した後、溶液中に尿素/NO3 -=4の割合で秤量した尿素を加え、更に攪拌して原料水溶液を得た。
テフロン(登録商標)製密閉容器(内容量100ml、外側がステンレス製ジャケット)に上記(3)で作製した原料水溶液と上記(2)で洗浄した多孔質基材を共に封入した。このとき、基材はテフロン(登録商標)製密閉容器の底から浮かせて固定し、基材両面に溶液が接するように水平に設置した。その後、水熱温度70℃で168時間(7日間)水熱処理を施すことにより基材表面に層状複水酸化物配向膜の形成を行った。所定時間の経過後、基材を密閉容器から取り出し、イオン交換水で洗浄し、70℃で10時間乾燥させて、層状複水酸化物(以下、LDHという)の緻密膜(以下、膜試料B1~B5という)を基材上に得た。得られた膜試料の厚さは約1.5μmであった。こうして、層状複水酸化物含有複合材料試料(以下、複合材料試料B1~B5という)を得た。なお、LDH膜は多孔質基材の両面に形成されていたが、セパレータとしての形態を複合材料に付与するため、多孔質基材の片面のLDH膜を機械的に削り取った。
X線回折装置(リガク社製 RINT TTR III)にて、電圧:50kV、電流値:300mA、測定範囲:10~70°の測定条件で、膜試料B2の結晶相を測定したところ、図6に示されるXRDプロファイルが得られた。得られたXRDプロファイルについて、JCPDSカードNO.35-0964に記載される層状複水酸化物(ハイドロタルサイト類化合物)の回折ピークを用いて同定した。その結果、膜試料B2は層状複水酸化物(LDH、ハイドロタルサイト類化合物)であることが確認された。なお、図6に示されるXRDプロファイルにおいては、膜試料B2が形成されている多孔質基材を構成するアルミナに起因するピーク(図中で○印が付されたピーク)も併せて観察されている。膜試料B1及びB3~B5についても同様に層状複水酸化物(LDH、ハイドロタルサイト類化合物)であることが確認された。
膜試料B2の表面微構造を走査型電子顕微鏡(SEM、JSM-6610LV、JEOL社製)を用いて10~20kVの加速電圧で観察した。得られた膜試料B2の表面微構造のSEM画像(二次電子像)を図7に示す。
膜試料B2について、画像処理を用いた手法により、膜の表面の気孔率を測定した。この気孔率の測定は、1)表面微構造を走査型電子顕微鏡(SEM、JSM-6610LV、JEOL社製)を用いて10~20kVの加速電圧で観察して膜の表面の電子顕微鏡(SEM)画像(倍率10000倍以上)を取得し、2)Photoshop(Adobe社製)等の画像解析ソフトを用いてグレースケールのSEM画像を読み込み、3)[イメージ]→[色調補正]→[2階調化]の手順で白黒の2値画像を作成し、4)黒い部分が占めるピクセル数を画像の全ピクセル数で割った値を気孔率(%)とすることにより行った。この気孔率の測定は膜試料表面の6μm×6μmの領域について行われた。その結果、膜の表面の気孔率は19.0%であった。また、この膜表面の気孔率を用いて、膜表面から見たときの密度D(以下、表面膜密度という)をD=100%-(膜表面の気孔率)により算出したところ、81.0%であった。
膜試料B1~B5が透水性を有しない程の緻密性を有することを確認すべく、緻密性判定試験を以下のとおり行った。まず、図9Aに示されるように、例B1において得られた複合材料試料120(1cm×1cm平方に切り出されたもの)の膜試料側に、中央に0.5cm×0.5cm平方の開口部22aを備えたシリコンゴム122を接着し、得られた積層物を2つのアクリル製容器124,126で挟んで接着した。シリコンゴム122側に配置されるアクリル製容器124は底が抜けており、それによりシリコンゴム122はその開口部122aが開放された状態でアクリル製容器124と接着される。一方、複合材料試料120の多孔質基材側に配置されるアクリル製容器126は底を有しており、その容器126内にはイオン交換水128が入っている。この時、イオン交換水にAl及び/又はMgを溶解させておいてもよい。すなわち、組み立て後に上下逆さにすることで、複合材料試料120の多孔質基材側にイオン交換水128が接するように各構成部材が配置されてなる。これらの構成部材等を組み立て後、総重量を測定した。なお、容器126には閉栓された通気穴(図示せず)が形成されており、上下逆さにした後に開栓されることはいうまでもない。図9Bに示されるように組み立て体を上下逆さに配置して25℃で1週間保持した後、総重量を再度測定した。このとき、アクリル製容器124の内側側面に水滴が付着している場合には、その水滴を拭き取った。そして、試験前後の総重量の差を算出することにより緻密度を判定した。その結果、25℃で1週間保持した後においても、イオン交換水の重量に変化は見られなかった。このことから、膜試料B1~B5(すなわち機能膜)はいずれも透水性を有しない程に高い緻密性を有することが確認された。
Claims (15)
- 水酸化物イオン伝導性を有し、かつ、単位面積あたりのHe透過度が10cm/min・atm以下である、水酸化物イオン伝導緻密膜。
- 前記He透過度が1.0cm/min・atm以下である、請求項1に記載の水酸化物イオン伝導緻密膜。
- 水接触下で評価した場合における単位面積あたりのZn透過割合が10m-2・h-1以下である、請求項1又は2に記載の水酸化物イオン伝導緻密膜。
- 前記Zn透過割合が1.0m-2・h-1以下である、請求項3に記載の水酸化物イオン伝導緻密膜。
- 水酸化物イオン伝導性を有する無機材料及び/又は有機材料を含んでなる、請求項1~4のいずれか一項に記載の水酸化物イオン伝導緻密膜。
- 水酸化物イオン伝導性を有する無機材料が、一般式:M2+ 1-xM3+ x(OH)2An- x/n・mH2O(式中、M2+は2価の陽イオン、M3+は3価の陽イオンであり、An-はn価の陰イオン、nは1以上の整数、xは0.1~0.4であり、mは0以上である)で表される層状複水酸化物を含んでなる、請求項5に記載の水酸化物イオン伝導緻密膜。
- 前記一般式において、少なくともM2+にMg2+を、M3+にAl3+を含み、An-にOH-及び/又はCO3 2-を含む、請求項6に記載の水酸化物イオン伝導緻密膜。
- 前記層状複水酸化物が複数の板状粒子の集合体で構成され、該複数の板状粒子がそれらの板面が前記緻密層と略垂直に又は斜めに交差するような向きに配向してなる、請求項6又は7に記載の水酸化物イオン伝導緻密膜。
- 100μm以下の厚さを有する、請求項1~8のいずれか一項に記載の水酸化物イオン伝導緻密膜。
- 多孔質基材と、該多孔質基材の少なくとも一方の表面に設けられる請求項1~9のいずれか一項に記載の水酸化物イオン伝導緻密膜とを備えた、複合材料。
- 前記多孔質基材が、セラミックス材料、金属材料、及び高分子材料からなる群から選択される少なくとも1種で構成される、請求項10に記載の複合材料。
- 前記多孔質基材が、セラミックス材料で構成され、該セラミックス材料が、アルミナ、ジルコニア、チタニア、マグネシア、スピネル、カルシア、コージライト、ゼオライト、ムライト、フェライト、酸化亜鉛、及び炭化ケイ素からなる群から選択される少なくとも1種である、請求項11に記載の複合材料。
- 前記多孔質基材が、0.001~1.5μmの平均気孔径を有する、請求項10~12のいずれか一項に記載の複合材料。
- 前記多孔質基材の表面が、10~60%の気孔率を有する、請求項10~13のいずれか一項に記載の複合材料。
- 請求項1~9のいずれか一項に記載の水酸化物イオン伝導緻密膜又は請求項10~14のいずれか一項に記載の複合材料をセパレータとして備えた、電池。
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CN201580002124.6A CN107210081A (zh) | 2015-01-28 | 2015-10-09 | 氢氧化物离子传导致密膜及复合材料 |
JP2016534267A JP6038410B1 (ja) | 2015-01-28 | 2015-10-09 | 水酸化物イオン伝導緻密膜及び複合材料 |
KR1020167014033A KR101681013B1 (ko) | 2015-01-28 | 2015-10-09 | 수산화물 이온 전도 치밀막 및 복합 재료 |
EP15862135.9A EP3252779A4 (en) | 2015-01-28 | 2015-10-09 | Hydroxide ion conducting dense film and composite material |
US15/164,982 US10193118B2 (en) | 2015-01-28 | 2016-05-26 | Hydroxide-ion-conductive dense membrane and composite material |
US16/112,887 US20180366708A1 (en) | 2015-01-28 | 2018-08-27 | Hydroxide-ion-conductive dense membrane and composite material |
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JP2015013914 | 2015-01-28 | ||
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US15/164,982 Continuation US10193118B2 (en) | 2015-01-28 | 2016-05-26 | Hydroxide-ion-conductive dense membrane and composite material |
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WO2016121168A1 true WO2016121168A1 (ja) | 2016-08-04 |
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US (2) | US10193118B2 (ja) |
EP (1) | EP3252779A4 (ja) |
JP (1) | JP6038410B1 (ja) |
KR (1) | KR101681013B1 (ja) |
CN (1) | CN107210081A (ja) |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2020098779A (ja) * | 2018-12-17 | 2020-06-25 | 日本碍子株式会社 | 電気化学セル |
US11545719B2 (en) * | 2017-12-18 | 2023-01-03 | Ngk Insulators, Ltd. | LDH separator and secondary zinc battery |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2019077952A1 (ja) * | 2017-10-20 | 2019-04-25 | 日本碍子株式会社 | 亜鉛二次電池 |
CN109546091B (zh) * | 2018-11-07 | 2021-10-26 | 超威电源集团有限公司 | 一种高比能量锌镍电池正极制备方法 |
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2015
- 2015-10-09 CN CN201580002124.6A patent/CN107210081A/zh active Pending
- 2015-10-09 KR KR1020167014033A patent/KR101681013B1/ko active IP Right Grant
- 2015-10-09 WO PCT/JP2015/078825 patent/WO2016121168A1/ja active Application Filing
- 2015-10-09 EP EP15862135.9A patent/EP3252779A4/en not_active Withdrawn
- 2015-10-09 JP JP2016534267A patent/JP6038410B1/ja active Active
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2016
- 2016-05-26 US US15/164,982 patent/US10193118B2/en active Active
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2018
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11545719B2 (en) * | 2017-12-18 | 2023-01-03 | Ngk Insulators, Ltd. | LDH separator and secondary zinc battery |
JP2020098779A (ja) * | 2018-12-17 | 2020-06-25 | 日本碍子株式会社 | 電気化学セル |
Also Published As
Publication number | Publication date |
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EP3252779A1 (en) | 2017-12-06 |
JP6038410B1 (ja) | 2016-12-07 |
JPWO2016121168A1 (ja) | 2017-04-27 |
US20180366708A1 (en) | 2018-12-20 |
CN107210081A (zh) | 2017-09-26 |
EP3252779A4 (en) | 2018-08-01 |
US10193118B2 (en) | 2019-01-29 |
KR20160106047A (ko) | 2016-09-09 |
US20160268568A1 (en) | 2016-09-15 |
KR101681013B1 (ko) | 2016-11-29 |
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