Sheet for thin layer transfer, electrode catalyst layer-carrying sheet for thin layer transfer, method for producing sheet for thin layer transfer, and method for producing membrane electrode assembly

Patent metadata

Field	Value
Publication number	US-2016276676-A1
Application number	US-201415027955-A
Country	US
Kind code	A1
Filing date	Jul 18, 2014
Priority date	Oct 11, 2013
Publication date	Sep 22, 2016
Grant date	—

Abstract

The present invention provides a sheet for thin layer transfer ( 10 ) including: a substrate ( 1 ) including a thin metal film or a thin heat-resistant resin film; and a fluorine resin layer ( 2 ) provided on at least one side of the substrate ( 1 ). The sheet for thin layer transfer thus provided can have reduced surface irregularities and be less prone to deteriorate even when subjected to repeated thermal transfer by thermocompression bonding.

First claim

1 . A sheet for thin layer transfer, comprising:
a substrate comprising a thin metal film or a thin heat-resistant resin film; and a fluorine resin layer provided on at least one side of the substrate.

2 . The sheet for thin layer transfer according to claim 1 , wherein the fluorine resin layer is provided on both sides of the substrate.

3 . The sheet for thin layer transfer according to claim 2 , wherein the fluorine resin layer is formed so as to have two portions respectively provided on both sides of the substrate, the two portions being connected to each other.

4 . The sheet for thin layer transfer according to claim 1 , wherein the substrate is a thin aluminum film or a thin stainless steel film.

5 . The sheet for thin layer transfer according to claim 1 , wherein the substrate is a thin polyimide film.

6 . The sheet for thin layer transfer according to claim 1 , wherein the fluorine resin layer is formed of a fluorine resin, the fluorine resin being polytetrafluoroethylene or tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer.

7 . The sheet for thin layer transfer according to claim 1 , wherein the fluorine resin layer is formed of a fluorine resin adhered directly to the substrate.

8 . The sheet for thin layer transfer according to claim 1 , having a surface formed by the fluorine resin layer, the surface having an arithmetic mean roughness Ra (JIS B 0601-1994) of 1 μm or less.

9 . The sheet for thin layer transfer according to claim 1 , having a tensile strength of 60 MPa or more.

10 . An electrode catalyst layer-carrying sheet for thin layer transfer, comprising:
the sheet for thin layer transfer according to claim 1 ; and an electrode catalyst layer for use in a membrane electrode assembly of a fuel cell, the electrode catalyst layer being stacked on the sheet for thin layer transfer.

11 . The electrode catalyst layer-carrying sheet for thin layer transfer according to claim 10 , wherein the electrode catalyst layer comprises at least a polymer electrolyte and catalytic material-supporting particles.

12 . A method for producing a sheet for thin layer transfer, the method comprising:
a step of providing a substrate including a thin metal film or a thin heat-resistant resin film; an immersion coating step of immersing the substrate in a dispersion of a fluorine resin; a heat drying step of, after the immersion coating step, heating a sheet including the substrate coated with the fluorine resin so as to remove a dispersion medium of the dispersion; and a sintering step of, after the heat drying step, heating the sheet at a temperature equal to or higher than a melting point of the fluorine resin.

13 . The method for producing a sheet for thin layer transfer according to claim 12 , comprising two to five repetitions of a sequence of steps consisting of the immersion coating step, the heat drying step, and the sintering step.

14 . A method for producing a membrane electrode assembly, the method comprising:
a catalyst layer stacking step of stacking an electrode catalyst layer including at least a polymer electrolyte and catalytic material-supporting particles on the sheet for thin layer transfer according to claim 1 ; an electrolyte membrane stacking step of bringing an electrolyte membrane into contact with the electrode catalyst layer stacked on the sheet for thin layer transfer; a thermocompression bonding step of bonding the electrode catalyst layer and the electrolyte membrane together by thermocompression; and a peeling step of peeling the sheet for thin layer transfer from the electrode catalyst layer.

Assignees

• Nitto Denko Corp

Inventors

• Kuroki Yuta

Classifications

• H01M8/1004

  characterised by membrane-electrode assemblies [MEA] (H01M8/12 takes precedence) · CPC title

• H01M4/8814 Primary

  Temporary supports, e.g. decal · CPC title

• H01M4/881

  Electrolytic membranes · CPC title

• B05D1/18

  performed by dipping · CPC title

• H01M4/8825

  Methods for deposition of the catalytic active composition · CPC title