WO2022126935A1 - 一种气体扩散层及制备方法 - Google Patents

一种气体扩散层及制备方法 Download PDF

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WO2022126935A1
WO2022126935A1 PCT/CN2021/085687 CN2021085687W WO2022126935A1 WO 2022126935 A1 WO2022126935 A1 WO 2022126935A1 CN 2021085687 W CN2021085687 W CN 2021085687W WO 2022126935 A1 WO2022126935 A1 WO 2022126935A1
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carbon fiber
substrate
conductive porous
hydrophobic
slurry
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PCT/CN2021/085687
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English (en)
French (fr)
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尧克光
徐少轶
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深圳市通用氢能科技有限公司
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Priority to US17/554,323 priority Critical patent/US12051813B2/en
Publication of WO2022126935A1 publication Critical patent/WO2022126935A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/88—Processes of manufacture
    • H01M4/8803—Supports for the deposition of the catalytic active composition
    • H01M4/8807—Gas diffusion layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/8605—Porous electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/8647—Inert electrodes with catalytic activity, e.g. for fuel cells consisting of more than one material, e.g. consisting of composites
    • H01M4/8657—Inert electrodes with catalytic activity, e.g. for fuel cells consisting of more than one material, e.g. consisting of composites layered
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • the invention relates to the technical field of fuel cells, in particular to a gas diffusion layer and a preparation method.
  • the gas diffusion layer plays an important role in supporting the catalytic layer, collecting current, conducting gas and discharging the reaction product water in the fuel cell.
  • the traditional gas diffusion layer includes a carbon fiber substrate and a microporous layer coated on the carbon fiber substrate. Since the gas diffusion layer needs to have good electrical conductivity, the carbon fiber substrate needs to be conductively treated.
  • the traditional method is to coat a layer of conductive material on the surface of the carbon fiber substrate to make the carbon fiber substrate conductive. It can be seen that the traditional method can only make the surface of the carbon fiber substrate have electrical conductivity, but cannot make the whole carbon fiber substrate have electrical conductivity, thereby affecting the performance of the gas diffusion layer.
  • the main purpose of the present invention is to provide a gas diffusion layer and a preparation method, aiming to solve the problem that the conductive treatment in the prior art can only make the surface of the carbon fiber substrate have electrical conductivity, but cannot make the entire carbon fiber substrate have electrical conductivity, There are technical problems that affect the performance of the gas diffusion layer.
  • the technical scheme provided by the present invention is:
  • a preparation method of a gas diffusion layer comprising:
  • a microporous layer is formed on the hydrophobic conductive porous substrate to obtain a gas diffusion layer.
  • the conductive material is added to the carbon fiber suspension slurry to obtain a carbon fiber substrate comprising:
  • the carbon fiber is chopped to obtain chopped carbon fiber
  • the base paper pulp is subjected to forming treatment to obtain a carbon fiber base material.
  • dispersing the chopped carbon fibers to obtain a carbon fiber suspension slurry comprises:
  • the chopped carbon fibers into a solution to obtain a carbon fiber mixture, wherein the solution includes a dispersant, a defoaming agent and a regulator;
  • the carbon fiber mixture is stirred for a preset time at a preset speed to obtain a carbon fiber suspension slurry.
  • the conductive material is added to the carbon fiber suspension slurry to obtain the base paper slurry comprising:
  • the cooled carbon fiber suspension slurry is stirred for a preset time at a preset speed to obtain a base paper slurry.
  • forming the base paper pulp to obtain a carbon fiber substrate comprises:
  • the base paper slurry is formed by an inclined wire former to obtain an initial carbon fiber substrate
  • processing the carbon fiber substrate to obtain a conductive porous substrate includes:
  • the carbon fiber base material after the heat treatment is subjected to a high-temperature carbonization treatment to obtain a conductive porous base material.
  • forming a hydrophobic layer on the conductive porous substrate to obtain a hydrophobic conductive porous substrate includes:
  • the dried conductive porous substrate is subjected to sintering treatment to obtain a hydrophobic conductive porous substrate.
  • forming a microporous layer on a hydrophobic conductive porous substrate to obtain a gas diffusion layer comprises:
  • the dried hydrophobic conductive porous substrate is sintered to obtain a gas diffusion layer.
  • preparing the microporous layer slurry includes:
  • the stirred porous material mixture is dispersed for a preset time at a preset speed to obtain a microporous layer slurry.
  • a gas diffusion layer comprising a microporous layer, a first hydrophobic layer, a conductive porous substrate and a second hydrophobic layer sequentially stacked from top to bottom, wherein the thickness of the gas diffusion layer is 80 ⁇ m-300 ⁇ m, and the tensile strength is 8MPa-30MPa, the volume resistance is 3m ⁇ cm 2 -10m ⁇ cm 2 , the porosity is more than 35%, and the contact angle is 100°-150°.
  • the present invention has the following beneficial effects:
  • the conductive material is directly added to the carbon fiber suspension slurry, so that the conductive material can be evenly distributed inside the carbon fiber base material, so that the conductive material and the carbon fiber can be better combined, thereby
  • the entire carbon fiber substrate is made conductive, thereby improving the performance of the gas diffusion layer.
  • the present application can avoid time consumption caused by coating the guide material, thereby saving production time and improving production efficiency.
  • the application of the present application makes the prepared gas diffusion layer less powdery and less prone to cracks under a certain pressure by closely fitting the carbon fiber substrate, the hydrophobic layer and the microporous layer, thereby improving the service life of the gas diffusion layer.
  • FIG. 1 is a flow chart of a method for preparing a gas diffusion layer according to an embodiment of the present invention
  • Fig. 2 is the flow chart of the step of obtaining carbon fiber base material according to one embodiment of the present invention
  • FIG. 3 is a flow chart of steps of obtaining a conductive porous substrate according to an embodiment of the present invention.
  • FIG. 4 is a flow chart of steps of obtaining a hydrophobic conductive porous substrate according to an embodiment of the present invention.
  • FIG. 5 is a flow chart of the steps of obtaining a gas diffusion layer according to an embodiment of the present invention.
  • FIG. 6 is a schematic diagram of a gas diffusion layer according to one embodiment of the present invention.
  • this embodiment provides a method for preparing a gas diffusion layer, which specifically includes the following steps:
  • the conductive material is added to the carbon fiber suspension slurry to obtain a carbon fiber base material.
  • S100 specifically includes the following steps:
  • chopped carbon fibers are processed to obtain chopped carbon fibers.
  • the carbon fiber filaments are chopped by a chopper to obtain chopped carbon fibers.
  • the length of the chopped carbon fibers is 3mm-10mm. This arrangement can avoid the high cost of producing the chopped carbon fibers due to the short length of the chopped carbon fibers. At the same time, it can avoid that the length of the chopped carbon fiber is too long and the dispersion effect of the chopped carbon fiber is poor, thereby affecting the performance of the carbon fiber substrate.
  • the chopped carbon fibers are put into a solution to obtain a carbon fiber mixture, wherein the solution includes a dispersant, an antifoaming agent and a regulator; the carbon fiber mixture is stirred at a preset speed for a preset time to obtain a carbon fiber suspension slurry.
  • the carbon fiber concentration in the carbon fiber mixture does not exceed 0.02%.
  • the conductive material is added to the carbon fiber suspension slurry to obtain a base paper slurry.
  • the carbon fiber suspension slurry is heated to a preset temperature.
  • the viscosity of the solids in the carbon fiber suspension slurry can be lowered, so that the solids in the carbon fiber suspension slurry can be dispersed more easily.
  • the conductive material, adhesive and glue are added to the heated carbon fiber suspension slurry.
  • the mixed carbon fiber suspension slurry is stirred for a preset time at a preset speed. Disperse the stirred carbon fiber suspension slurry at a preset speed for a preset time. Cool the dispersed carbon fiber suspension to a preset temperature.
  • This arrangement can cause the dispersed carbon fiber suspension slurry to undergo a hydration reaction, so that the solid dispersion in the carbon fiber suspension slurry is more uniform, thereby ensuring the performance of the carbon fiber substrate.
  • the cooled carbon fiber suspension slurry is stirred for a preset time at a preset speed to obtain a base paper slurry.
  • the raw paper pulp is formed by an inclined wire former to obtain an initial carbon fiber base material. Sizing the initial carbon fiber substrate to obtain a carbon fiber substrate.
  • the upper surface of the initial carbon fiber substrate is sized by a sizing machine, and the glue on the upper surface of the initial carbon fiber substrate can be better penetrated to the lower surface of the initial carbon fiber substrate by a suction machine. , so that the glue evenly distributed inside the carbon fiber substrate can better bond the entire carbon fiber substrate together, thereby improving the performance of the carbon fiber substrate.
  • S200 specifically includes the following steps:
  • the impregnated carbon fiber substrate is dried for 1h-5h at a temperature of 50°C to 150°C.
  • the impregnated carbon fiber substrate is dried for 5 to 30 minutes at a temperature of 50°C to 150°C.
  • the drying temperature is 50°C ⁇ 150°C, which can avoid the long drying time of the carbon fiber substrate due to the too low drying temperature, thus affecting the production efficiency of the gas diffusion layer; at the same time, it can avoid the problem that the drying temperature If it is too high, the surface of the carbon fiber substrate is prone to conjunctiva, so that the solvent inside the carbon fiber substrate cannot be dried, thereby affecting the yield of the gas diffusion layer.
  • the drying time is 5min-30min, which can avoid the problem that the carbon fiber substrate is not completely dried due to the short drying time, thereby affecting the performance of the gas diffusion layer; Production efficiency of diffusion layers.
  • the dried carbon fiber substrate is sintered at a temperature of 200° C. to 400° C. for 3 minutes to 30 minutes, wherein the atmosphere during sintering is air.
  • the dried carbon fiber substrate is treated at a temperature of 200° C. to 400° C. for 3 min to 30 min.
  • the heat treatment temperature is 200°C ⁇ 400°C, which can avoid the incomplete reaction of the carbon fiber substrate due to the low heat treatment temperature, thereby affecting the performance of the gas diffusion layer; at the same time, it can avoid the carbon fiber caused by the heat treatment temperature being too high.
  • the heat treatment time is 3min-30min, which can avoid the incomplete reaction of the carbon fiber substrate due to the short heat treatment time, thereby affecting the performance of the gas diffusion layer; at the same time, it can avoid the influence of the gas diffusion layer due to the long heat treatment time. production efficiency.
  • the carbon fiber base material after heat treatment is carbonized for 0.2 h to 2 h under the temperature condition of 1000° C. to 2000° C., wherein the atmosphere during carbonization is protective gas.
  • the carbon fiber substrate after the heat treatment is carbonized for 0.2 h to 2 h under the temperature condition of 1000° C. ⁇ 2000° C.
  • the temperature of carbonization treatment is 1000°C ⁇ 2000°C, which can avoid the incomplete reaction of the carbon fiber substrate due to the too low temperature of the carbonization treatment, thereby affecting the performance of the gas diffusion layer; at the same time, it can avoid the problem that the temperature of the carbonization treatment is too high This leads to the problem of high power consumption of the carbonization furnace.
  • the carbonization treatment time is 0.2h to 2h, which can avoid the incomplete reaction of the carbon fiber substrate due to the short carbonization treatment time, thereby affecting the performance of the gas diffusion layer; This leads to the problem of high power consumption of the carbonization furnace.
  • the protective gas includes but is not limited to any one of nitrogen, argon, and helium.
  • S300 specifically includes the following steps:
  • the conductive porous substrate is put into a hydrophobic agent for dipping treatment.
  • the conductive porous substrate is made to pass through the hydrophobic agent, the squeezing roller, the drying furnace and the sintering furnace in the dipping tank in sequence through the winding and unwinding system.
  • the excess hydrophobic agent on the conductive porous substrate can be removed by the squeezing roller, so that the hydrophobic agent on the conductive porous substrate can be controlled within a certain range, thereby ensuring the performance of the gas diffusion layer.
  • the surface of the conductive porous substrate after passing through the dipping tank does not come into contact with the drying furnace.
  • the solid content of the hydrophobic agent is 1%-20%. This setting can prevent the viscosity of the hydrophobic agent from being low due to too little solid content of the hydrophobic agent, so that the feeding amount of the hydrophobic agent is low, thereby affecting the gas diffusion layer. performance. At the same time, it can avoid the problem that the viscosity of the hydrophobic agent is high due to the too high solid content of the hydrophobic agent, and the feeding amount of the hydrophobic agent is large, thereby affecting the performance of the gas diffusion layer.
  • S400 specifically includes the following steps:
  • the microporous layer slurry can be uniformly adhered to the hydrophobic conductive porous substrate, so that the microporous layer and the proton exchange membrane can be closely attached, and the contact between the microporous layer and the proton exchange membrane can be reduced. resistance, thereby enhancing the performance of the fuel cell.
  • the solid content of the microporous layer slurry is 5%-25%. This arrangement can avoid the problem that the viscosity of the microporous layer slurry is low due to the too small solid content of the microporous layer slurry, so that the feeding amount of the microporous layer slurry is low, thereby affecting the performance of the gas diffusion layer. At the same time, it can avoid the problem that the viscosity of the microporous layer slurry is too high due to the high solid content of the microporous layer slurry, so that the feeding amount of the microporous layer slurry is large, thereby affecting the performance of the gas diffusion layer.
  • the microporous layer slurry is adhered on the hydrophobic conductive porous substrate by at least one of blade coating, ultrasonic spraying, screen printing, dipping and transfer printing, chemical vapor deposition and physical vapor deposition .
  • the adhered hydrophobic conductive porous substrate is passed through a drying furnace and a sintering furnace in sequence through a winding and unwinding system.
  • the coated surface of the hydrophobic conductive porous substrate does not contact the drying furnace and the sintering furnace.
  • the conductive material is directly added to the carbon fiber suspension slurry, so that the conductive material can be evenly distributed inside the carbon fiber base material, so that the conductive material and the carbon fiber can be better combined,
  • the entire carbon fiber base material has electrical conductivity, thereby improving the performance of the gas diffusion layer.
  • this embodiment can avoid time consumption caused by coating the guide material, thereby saving production time and improving production efficiency.
  • the carbon fiber base material, the hydrophobic layer and the microporous layer are closely attached, so that the prepared gas diffusion layer is not easy to lose powder, and cracks are not easily generated under a certain pressure, thereby improving the service life of the gas diffusion layer.
  • the carbon fiber is selected from T300 or T700 strength carbon fiber with good electrical conductivity.
  • the glue includes any one of the following: starch, modified starch, animal glue, modified cellulose, chitosan and its modifications, polyvinyl alcohol, polyacrylamide, alkyl ketene dimer, polyurethane, benzene Ethylene-maleic anhydride, styrene acrylic copolymer and styrene acrylate polymer.
  • Conductive materials include, but are not limited to, any one of graphene, graphite, carbon nanotubes, and carbon powder.
  • Thickeners include, but are not limited to, any one of hydroxypropylmethylcellulose, sodium carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, polyvinyl alcohol, and polyacrylamide.
  • Adhesives include, but are not limited to, any of epoxy resins, phenolic resins, acrylic resins, polyvinylpyrrolidone, polyurethane, and vinyl-containing polymer hot melt adhesives.
  • the hydrophobic agent includes, but is not limited to, any one of polytetrafluoroethylene, tetrafluoroethylene-hexafluoropropylene copolymer, polyvinylidene fluoride, and polysilazane resin.
  • a gas diffusion layer 10 which includes a microporous layer 1 , a first hydrophobic layer 2 , a conductive porous substrate 3 and a second hydrophobic layer sequentially stacked from top to bottom Layer 4, the thickness of the gas diffusion layer 10 is 80 ⁇ m-300 ⁇ m, the tensile strength of the gas diffusion layer 10 is 8MPa-30MPa, the volume resistance of the gas diffusion layer 10 is 3m ⁇ cm 2 -10m ⁇ cm 2 , the The porosity is 35% or more, and the contact angle of the gas diffusion layer 10 is 100°-150°.
  • the carbon fiber selects 10Kg of carbon fiber with a strength of T300 or T700, and chops the carbon fiber to obtain a chopped carbon fiber with a length of 6mm. Dispersing agent, defoaming agent and thickening agent, resulting in carbon fiber mixture. Wherein, the carbon fiber concentration in the carbon fiber mixture does not exceed 0.02%.
  • the carbon fiber mixture in the dispersion tank was stirred for 1 h at a speed of 100 rpm, so that the chopped carbon fibers in the carbon fiber mixture were completely dispersed into single carbon fibers, and a carbon fiber suspension slurry was obtained.
  • the base paper pulp is sucked to the inclined mesh former, and the inclined mesh former adopts a 40 mesh forming mesh belt, so that the initial carbon fiber base material can be uniform as a whole.
  • the initial carbon fiber substrate is sizing (upper sizing, lower suction) to obtain a carbon fiber substrate, and the carbon fiber substrate is successively dried by a drying furnace with a temperature of 70°C for 5min-20min and a temperature of 360°C through the rewinding and unwinding system.
  • °C of sintering furnace sintering 5min-30min and temperature of 2000 °C nitrogen atmosphere carbonization furnace carbonization 20min-50min, to obtain the conductive porous substrate.
  • the conductive porous substrate is successively passed through a 2%-15% PTFE dispersion dipping tank, a drying oven with a temperature of 70°C for 5min-20min, and a sintering oven with a temperature of 360°C for sintering. 5min-30min to obtain a hydrophobic conductive porous substrate.
  • the mass is successively dried in a drying furnace at a temperature of 80°C for 5min-20min, and a sintering furnace at a temperature of 365°C for 10min-60min, wherein the coating surface of the hydrophobic conductive porous substrate does not contact the drying furnace and the sintering furnace.
  • the contact angle between the gas diffusion layer and water obtained in this example is 150°
  • the volume resistance of the gas diffusion layer under a pressure of 0.6 MPa is 5.5 m ⁇ cm 2
  • the tensile strength of the gas diffusion layer is 13 MPa.

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Abstract

一种气体扩散层及制备方法，该气体扩散层的制备方法包括：将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材（S100）；对所述碳纤维基材进行处理，得到导电多孔质基材（S200）；在所述导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材（S300）；在疏水的导电多孔质基材上形成微孔层，得到气体扩散层（S400）。在制备碳纤维基材的过程中，直接将导电材料加入至碳纤维悬浮浆料中，以使导电材料能够均布分布在碳纤维基材的内部，使得导电材料和碳纤维能够更好地结合，从而使碳纤维基材的整体具有导电性，进而提高了气体扩散层的性能。并且能够避免因涂覆导向材料而造成的时间消耗，从而能够节省生产时间，提高生产效率。

Description

一种气体扩散层及制备方法 技术领域
本发明涉及燃料电池技术领域，特别涉及一种气体扩散层及制备方法。
背景技术
气体扩散层在燃料电池中起到支撑催化层、收集电流、传导气体和排出反应产物水的重要作用。传统的气体扩散层包括碳纤维基材以及涂覆在碳纤维基材上的微孔层，由于气体扩散层需要具有良好的导电性，因此需要对碳纤维基材进行导电处理。传统的做法是在碳纤维基材的表面涂覆一层导电材料，使得碳纤维基材具有导电性。可见，传统的做法只能使碳纤维基材的表面具有导电性，而不能使碳纤维基材的整体具有导电性，从而影响气体扩散层的性能。
发明内容
本发明的主要目的在于提供一种气体扩散层及制备方法，旨在解决现有技术中的导电处理只能使碳纤维基材的表面具有导电性，而不能使碳纤维基材的整体具有导电性，从而影响气体扩散层的性能的技术问题。
为了解决上述技术问题，本发明提供的技术方案为：
一种气体扩散层的制备方法，包括：
将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材；
对所述碳纤维基材进行处理，得到导电多孔质基材；
在所述导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材；
在疏水的导电多孔质基材上形成微孔层，得到气体扩散层。
优选地，将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材包括：
对碳纤维进行短切处理，得到短切碳纤维；
对所述短切碳纤维进行分散处理，得到碳纤维悬浮浆料；
将导电材料加入至所述碳纤维悬浮浆料中，得到原纸浆料；
对所述原纸浆料进行成型处理，得到碳纤维基材。
优选地，对所述短切碳纤维进行分散处理，得到碳纤维悬浮浆料包括：
将所述短切碳纤维放入溶液中，得到碳纤维混合物，其中，所述溶液包括分散剂、消泡剂以及增调剂；
以预设速度对所述碳纤维混合物搅拌预设时间，得到碳纤维悬浮浆料。
优选地，将导电材料加入至所述碳纤维悬浮浆料中，得到原纸浆料包括：
将所述碳纤维悬浮浆料加热至预设温度；
将导电材料、粘接剂以及胶液加入至加热后的碳纤维悬浮浆料中；
以预设速度对混合后的碳纤维悬浮浆料搅拌预设时间；
以预设速度对搅拌后的碳纤维悬浮浆料分散预设时间；
将分散后的碳纤维悬浮浆料冷却至预设温度；
以预设速度对冷却后的碳纤维悬浮浆料搅拌预设时间，得到原纸浆料。
优选地，对所述原纸浆料进行成型处理，得到碳纤维基材包括：
通过斜网成型器对所述原纸浆料进行成型，得到初始的碳纤维基材；
对初始的碳纤维基材进行施胶，得到碳纤维基材。
优选地，对所述碳纤维基材进行处理，得到导电多孔质基材包括：
对碳纤维基材进行干燥处理；
对干燥后的碳纤维基材进行热处理；
对热处理后的碳纤维基材进行高温碳化处理，得到导电多孔质基材。
优选地，在所述导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材包括：
将导电多孔质基材放入疏水剂中进行浸渍处理；
对浸渍后的导电多孔质基材进行干燥处理；
对干燥后的导电多孔质基材进烧结处理，得到疏水的导电多孔质基材。
优选地，在疏水的导电多孔质基材上形成微孔层，得到气体扩散层包括：
制备微孔层浆料；
将所述微孔层浆料粘附在疏水的导电多孔质基材上；
对粘附后的疏水的导电多孔质基材进行干燥处理；
对干燥后的疏水的导电多孔质基材进行烧结处理，得到气体扩散层。
优选地，制备微孔层浆料包括：
将碳材料、增稠剂、疏水剂加入液体中，得到多孔材料混合物；
以预设速度对所述多孔材料混合物搅拌预设时间；
以预设速度对搅拌后的多孔材料混合物分散预设时间，得到微孔层浆料。
一种气体扩散层，包括从上至下依次层叠的微孔层、第一疏水层、导电多孔质基材以及第二疏水层，所述气体扩散层的厚度为80μm-300μm，拉伸强度为8MPa-30MPa，体电阻为3mΩ·cm 2-10mΩ·cm 2，孔隙率为35％以上，接触角为100°-150°。
与现有技术相比，本发明具有以下有益效果：
本申请在制备碳纤维基材的过程中，直接将导电材料加入至碳纤维悬浮浆料中，以使导电材料能够均布分布在碳纤维基材的内部，使得导电材料和碳纤维能够更好地结合，从而使碳纤维基材的整体具有导电性，进而提高了气体扩散层的性能。并且本申请能够避免因涂覆导向材料而造成的时间消耗，从而能够节省生产时间，提高生产效率。并且本申请通过紧密贴合的碳纤维基材、疏水层以及微孔层，使得制备的气体扩散层不易掉粉，在一定压力下不易产生裂缝，从而提高了气体扩散层的使用寿命。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图示出的结构获得其他的附图。
图1是根据本发明的一个实施例的气体扩散层的制备方法的流程图；
图2是根据本发明的一个实施例的得到碳纤维基材步骤的流程图；
图3是根据本发明的一个实施例的得到导电多孔质基材步骤的流程图；
图4是根据本发明的一个实施例的得到疏水的导电多孔质基材步骤的流程图；
图5是根据本发明的一个实施例的得到气体扩散层步骤的流程图；
图6是根据本发明的一个实施例的气体扩散层的示意图。
10、气体扩散层；1、微孔层；2、第一疏水层；3、导电多孔质基材；4、 第二疏水层。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
需要说明，本发明实施例中所有方向性指示(诸如上、下、左、右、前、后……)仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等，如果该特定姿态发生改变时，则该方向性指示也相应地随之改变。
另外，在本发明中涉及“第一”、“第二”等的描述仅用于描述目的，而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外，全文中的“和/或”包括三个方案，以A和/或B为例，包括A技术方案、B技术方案，以及A和B同时满足的技术方案；另外，各个实施例之间的技术方案可以相互结合，但是必须是以本领域普通技术人员能够实现为基础，当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在，也不在本发明要求的保护范围之内。
如图1所示，本实施例提供了一种气体扩散层的制备方法，该制备方法具体包括以下步骤：
S100，将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材。
如图2所示，S100具体包括以下步骤：
S101，对碳纤维进行短切处理，得到短切碳纤维。
具体地，通过短切机对碳纤维长丝进行短切，得到短切碳纤维。
进一步地，短切碳纤维的长度为3mm-10mm。如此设置，能够避免因短切碳纤维的长度太短而导致生产短切碳纤维的成本较高。同时能够避免因短切碳纤维的长度太长而导致短切碳纤维的分散效果较差，从而影响碳纤维基材的性能。
S102，对短切碳纤维进行分散处理，得到碳纤维悬浮浆料。
具体地，将短切碳纤维放入溶液中，得到碳纤维混合物，其中，溶液包括分散剂、消泡剂以及增调剂；以预设速度对碳纤维混合物搅拌预设时间，得到碳纤维悬浮浆料。
进一步地，碳纤维混合物中的碳纤维浓度不超过0.02％。
S103，将导电材料加入至碳纤维悬浮浆料中，得到原纸浆料。
具体地，将碳纤维悬浮浆料加热至预设温度。如此设置，能够使碳纤维悬浮浆料中的固体粘度变低，使得碳纤维悬浮浆料中的固体更容易分散。将导电材料、粘接剂以及胶液加入至加热后的碳纤维悬浮浆料中。以预设速度对混合后的碳纤维悬浮浆料搅拌预设时间。以预设速度对搅拌后的碳纤维悬浮浆料分散预设时间。将分散后的碳纤维悬浮浆料冷却至预设温度。如此设置，能够使分散后的碳纤维悬浮浆料发生水合反应，使得碳纤维悬浮浆料中的固体分散更均匀，从而保证碳纤维基材的性能。以预设速度对冷却后的碳纤维悬浮浆料搅拌预设时间，得到原纸浆料。
S104，对原纸浆料进行成型处理，得到碳纤维基材。
具体地，通过斜网成型器对原纸浆料进行成型，得到初始的碳纤维基材。对初始的碳纤维基材进行施胶，得到碳纤维基材。
进一步地，通过施胶机对初始的碳纤维基材的上表面进行施胶，通过抽吸机使初始的碳纤维基材的上表面的胶液能够更好地渗透至初始的碳纤维基材的下表面，使得均布分布在碳纤维基材内部的胶液能够将整个碳纤维基材更好地粘合在一起，从而提高了碳纤维基材的性能。
S200，对碳纤维基材进行处理，得到导电多孔质基材。
如图3所示，S200具体包括以下步骤：
S201，对碳纤维基材进行干燥处理。
在50℃～150℃的温度条件下对浸渍后的碳纤维基材干燥1h-5h。
具体地，在50℃～150℃的温度条件下对浸渍后的碳纤维基材干燥5min-30min。干燥处理的温度为50℃～150℃，能够避免因干燥处理的温度过低而导致碳纤维基材干燥的时间较长，从而影响气体扩散层的生产效率的问题；同时能够避免因干燥处理的温度过高而导致碳纤维基材的表面容易结膜，使得碳纤维基材内部的溶剂无法被干燥，从而影响气体扩散层的良品率的问题。干燥处理的时间为5min-30min，能够避免因干燥处理的时间过短而导致 碳纤维基材干燥不完全，从而影响气体扩散层的性能的问题；同时能够避免因干燥处理的时间过长而影响气体扩散层的生产效率。
S202，对干燥后的碳纤维基材进行热处理。
在200℃～400℃的温度条件下对干燥后的碳纤维基材烧结3min-30min，其中，烧结时的气氛为空气。
具体地，在200℃～400℃的温度条件下对干燥后的碳纤维基材处理3min-30min。热处理的温度为200℃～400℃，能够避免因热处理的温度过低而导致碳纤维基材的反应不完全，从而影响气体扩散层的性能的问题；同时能够避免因热处理的温度过高而导致碳纤维基材燃烧。热处理的时间为3min-30min，能够避免因热处理的时间过短而导致碳纤维基材的反应不完全，从而影响气体扩散层的性能的问题；同时能够避免因热处理的时间过长而影响气体扩散层的生产效率。
S203，对热处理后的碳纤维基材进行高温碳化处理，得到导电多孔质基材。
在1000℃～2000℃的温度条件下对热处理后的碳纤维基材碳化0.2h～2h，其中，碳化时的气氛为保护气。
具体地，在1000℃～2000℃的温度条件下对热处理后的碳纤维基材碳化0.2h～2h。碳化处理的温度为1000℃～2000℃，能够避免因碳化处理的温度过低而导致碳纤维基材的反应不完全，从而影响气体扩散层的性能的问题；同时能够避免因碳化处理的温度过高而导致碳化炉功耗较高的问题。碳化处理的时间为0.2h～2h，能够避免因碳化处理的时间过短而导致碳纤维基材的反应不完全，从而影响气体扩散层的性能的问题；同时能够避免因碳化处理的时间过长而导致碳化炉功耗较高的问题。
具体地，保护气包括但不限于氮气、氩气、氦气中的任意一种。
S300，在导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材。
如图4所示，S300具体包括以下步骤：
S301，将导电多孔质基材放入疏水剂中进行浸渍处理。
具体地，通过收放卷系统使导电多孔质基材依次经过浸渍槽内的疏水剂、挤水辊、干燥炉以及烧结炉。通过挤水辊能够去除导电多孔质基材上多余的疏水剂，使得导电多孔质基材上的疏水剂能够控制在一定范围内，从而保证 气体扩散层的性能。
进一步地，经过浸渍槽后的导电多孔质基材的表面不接触干燥炉。
疏水剂的固含量为1％-20％，如此设置，能够避免因疏水剂的固含量太少而导致疏水剂的粘度较低，使得疏水剂的上料量较低，从而影响气体扩散层的性能。同时能够避免因疏水剂的固含量太高而导致疏水剂的粘度较大，使得疏水剂的上料量较大，从而影响气体扩散层的性能的问题。
S302，对浸渍后的导电多孔质基材进行干燥处理。
S303，对干燥后的导电多孔质基材进烧结处理，得到疏水的导电多孔质基材。
S400，在疏水的导电多孔质基材上形成微孔层，得到气体扩散层。
如图5所示，S400具体包括以下步骤：
S401，制备微孔层浆料。
具体地，将多孔材料、增稠剂、疏水剂加入液体中，得到多孔材料混合物；以预设速度对多孔材料混合物搅拌预设时间；以预设速度对搅拌后的多孔材料混合物分散预设时间，得到微孔层浆料。如此设置，能够使微孔层浆料均匀粘附在疏水的导电多孔质基材上，使得微孔层和质子交换膜能够紧密贴合，能够减小微孔层和质子交换膜之间的接触电阻，从而增强燃料电池的性能。
微孔层浆料的固含量为5％-25％。如此设置，能够避免因微孔层浆料的固含量太少而导致微孔层浆料的粘度较低，使得微孔层浆料的上料量较低，从而影响气体扩散层的性能的问题；同时能够避免因微孔层浆料的固含量太高而导致微孔层浆料的粘度较大，使得微孔层浆料的上料量较大，从而影响气体扩散层的性能的问题。
S402，将微孔层浆料粘附在疏水的导电多孔质基材上。
具体地，利用刮涂、超声喷涂、丝网印刷、浸渍和转印、化学气相沉积和物理气相沉积中的至少一种方式，将微孔层浆料粘附在疏水的导电多孔质基材上。
S403，对粘附后的疏水的导电多孔质基材进行干燥处理。
S404，对干燥后的疏水的导电多孔质基材进行烧结处理，得到气体扩散层。
具体地，通过收放卷系统使粘附后的疏水的导电多孔质基材依次经过干燥炉和烧结炉。
进一步地，疏水的导电多孔质基的涂覆面不接触干燥炉和烧结炉。
本实施例在制备碳纤维基材的过程中，直接将导电材料加入至碳纤维悬浮浆料中，以使导电材料能够均布分布在碳纤维基材的内部，使得导电材料和碳纤维能够更好地结合，从而使碳纤维基材的整体具有导电性，进而提高了气体扩散层的性能。并且本实施例能够避免因涂覆导向材料而造成的时间消耗，从而能够节省生产时间，提高生产效率。并且本实施例通过紧密贴合的碳纤维基材、疏水层以及微孔层，使得制备的气体扩散层不易掉粉，在一定压力下不易产生裂缝，从而提高了气体扩散层的使用寿命。
碳纤维选用导电性良好的T300或T700强度碳纤维。
胶液包括以下任意之一：淀粉、改性淀粉、动物胶、改性纤维素、壳聚糖及其改性物、聚乙烯醇、聚丙烯酰胺、烷基烯酮二聚体、聚氨酯、苯乙烯-马来酸酐、苯乙烯丙烯酸共聚物以及苯乙烯丙烯酸酯聚合物。
导电材料包括但不限于石墨烯、石墨、碳纳米管以及炭粉中的任意一种。
增稠剂包括但不限于羟丙基甲基纤维素、羧甲基纤维素钠、羟乙基纤维素、甲基纤维素、聚乙烯醇以及聚丙烯酰胺中的任意一种。
粘接剂包括但不限于环氧树脂、酚醛树脂、丙烯酸树脂、聚乙烯吡咯烷酮、聚氨酯以及含乙烯聚合物的热熔粘结剂中的任意一种。
疏水剂包括但不限于聚四氟乙烯、四氟乙烯-六氟丙烯共聚物、聚偏二氟乙烯、聚硅氮烷树脂中的任意一种。
如图6所示，在一个实施例中，提供了一种气体扩散层10，包括从上至下依次层叠的微孔层1、第一疏水层2、导电多孔质基材3以及第二疏水层4，气体扩散层10的厚度为80μm-300μm，气体扩散层10的拉伸强度为8MPa-30MPa，气体扩散层10的体电阻为3mΩ·cm 2-10mΩ·cm 2，气体扩散层10的孔隙率为35％以上，气体扩散层10的接触角为100°-150°。
下面结合实施例对本发明进一步详细说明。
实施一：
碳纤维选择T300或T700强度的碳纤维10Kg，对碳纤维进行短切处理，得到长度为6mm的短切碳纤维，短切碳纤维首先经过料仓自动进入带搅拌器 的分散罐中，向分散罐中加入水、分散剂、消泡剂以及增稠剂，得到碳纤维混合物。其中，碳纤维混合物中的碳纤维浓度不超过0.02％。以100rpm的速度对分散罐中的碳纤维混合物搅拌1h，使得碳纤维混合物中的短切碳纤维完全分散为单根碳纤维，得到碳纤维悬浮浆料。将碳纤维悬浮浆料加热至80℃-90℃，将1.3Kg-2.3Kg碳粉、1Kg-2Kg环氧树脂、1Kg-2Kg改性物等天然高分子表面施胶剂混合均匀后加入至加热后的12Kg-18Kg碳纤维悬浮浆料中。以1000rpm的速度对混合后的碳纤维悬浮浆料搅拌1h，以4000rpm的速度对混合后的碳纤维悬浮浆料分散3h，将分散后的碳纤维悬浮浆料冷却至25℃，以300rpm的速度对冷却后的碳纤维悬浮浆料搅拌1h，得到分散均匀的原纸浆料。将原纸浆料抽吸至斜网成型器上，斜网成型器采用40目的成型网带，使初始的碳纤维基材能够整体均匀。对初始的碳纤维基材进行施胶(上施胶，下抽吸)，得到碳纤维基材，通过收放卷系统使碳纤维基材依次经过温度为70℃的干燥炉干燥5min-20min、温度为360℃的烧结炉烧结5min-30min以及温度为2000℃的氮气氛碳化炉碳化20min-50min，得到导电多孔质基材。通过收放卷系统使导电多孔质基材依次经过浓度为2％-15％的聚四氟乙烯分散液浸渍槽、温度为70℃的干燥炉干燥5min-20min、温度为360℃的烧结炉烧结5min-30min，得到疏水的导电多孔质基材。
将1Kg-2Kg碳黑、0.2Kg-1Kg聚四氟乙烯悬浮液和0.1Kg-0.6Kg纤维素混合均匀后加入13Kg-19Kg水中，得到碳黑混合物；以2000rpm的速度对碳黑混合物搅拌1h，再以4000rpm的速度对搅拌后的碳黑混合物分散3h，得到分散均匀的微孔层浆料。通过调节涂布机的涂布头厚度，使微孔层浆料以20μm-200μm的厚度均匀涂覆在疏水的导电多孔质基材一面，通过收放卷系统使涂覆后的疏水的导电多孔质依次经过温度为80℃的干燥炉干燥5min-20min、温度为365℃的烧结炉烧结10min-60min，其中，疏水的导电多孔质基的涂覆面不接触干燥炉和烧结炉。
本实施例得到的气体扩散层和水的接触角为150°，气体扩散层在0.6MPa压力下的体电阻为5.5mΩ·cm 2、气体扩散层的拉伸强度为13MPa。
以上所述仅为本发明的优选实施例，并非因此限制本发明的专利范围，凡是在本发明的发明构思下，利用本发明说明书及附图内容所作的等效结构变换，或直接/间接运用在其他相关的技术领域均包括在本发明的专利保护范 围内。

Claims (10)

  1. 一种气体扩散层的制备方法，其特征在于，包括：
    将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材；
    对所述碳纤维基材进行处理，得到导电多孔质基材；
    在所述导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材；
    在疏水的导电多孔质基材上形成微孔层，得到气体扩散层。
  2. 根据权利要求1所述的制备方法，其特征在于：将导电材料加入至碳纤维悬浮浆料中，得到碳纤维基材包括：
    对碳纤维进行短切处理，得到短切碳纤维；
    对所述短切碳纤维进行分散处理，得到碳纤维悬浮浆料；
    将导电材料加入至所述碳纤维悬浮浆料中，得到原纸浆料；
    对所述原纸浆料进行成型处理，得到碳纤维基材。
  3. 根据权利要求2所述的制备方法，其特征在于：对所述短切碳纤维进行分散处理，得到碳纤维悬浮浆料包括：
    将所述短切碳纤维放入溶液中，得到碳纤维混合物，其中，所述溶液包括分散剂、消泡剂以及增调剂；
    以预设速度对所述碳纤维混合物搅拌预设时间，得到碳纤维悬浮浆料。
  4. 根据权利要求2所述的制备方法，其特征在于：将导电材料加入至所述碳纤维悬浮浆料中，得到原纸浆料包括：
    将所述碳纤维悬浮浆料加热至预设温度；
    将导电材料、粘接剂以及胶液加入至加热后的碳纤维悬浮浆料中；
    以预设速度对混合后的碳纤维悬浮浆料搅拌预设时间；
    以预设速度对搅拌后的碳纤维悬浮浆料分散预设时间；
    将分散后的碳纤维悬浮浆料冷却至预设温度；
    以预设速度对冷却后的碳纤维悬浮浆料搅拌预设时间，得到原纸浆料。
  5. 根据权利要求2所述的制备方法，其特征在于：对所述原纸浆料进行成型处理，得到碳纤维基材包括：
    通过斜网成型器对所述原纸浆料进行成型，得到初始的碳纤维基材；
    对初始的碳纤维基材进行施胶，得到碳纤维基材。
  6. 根据权利要求1所述的制备方法，其特征在于：对所述碳纤维基材进行处理，得到导电多孔质基材包括：
    对碳纤维基材进行干燥处理；
    对干燥后的碳纤维基材进行热处理；
    对热处理后的碳纤维基材进行高温碳化处理，得到导电多孔质基材。
  7. 根据权利要求1所述的制备方法，其特征在于：在所述导电多孔质基材上形成疏水层，得到疏水的导电多孔质基材包括：
    将导电多孔质基材放入疏水剂中进行浸渍处理；
    对浸渍后的导电多孔质基材进行干燥处理；
    对干燥后的导电多孔质基材进烧结处理，得到疏水的导电多孔质基材。
  8. 根据权利要求1所述的制备方法，其特征在于：在疏水的导电多孔质基材上形成微孔层，得到气体扩散层包括：
    制备微孔层浆料；
    将所述微孔层浆料粘附在疏水的导电多孔质基材上；
    对粘附后的疏水的导电多孔质基材进行干燥处理；
    对干燥后的疏水的导电多孔质基材进行烧结处理，得到气体扩散层。
  9. 根据权利要求8所述的制备方法，其特征在于：制备微孔层浆料包括：
    将多孔材料、增稠剂、疏水剂加入液体中，得到多孔材料混合物；
    以预设速度对所述多孔材料混合物搅拌预设时间；
    以预设速度对搅拌后的多孔材料混合物分散预设时间，得到微孔层浆料。
  10. 一种气体扩散层，其特征在于，包括从上至下依次层叠的微孔层、第一疏水层、导电多孔质基材以及第二疏水层，所述气体扩散层的厚度为80μm-300μm，拉伸强度为8MPa-30MPa，体电阻为3mΩ·cm 2-10mΩ·cm 2，孔隙率为35％以上，接触角为100°-150°。
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