Carbon sheet, gas diffusion electrode substrate and fuel cell

Patent metadata

Field	Value
Publication number	US-2017244107-A1
Application number	US-201515518939-A
Country	US
Kind code	A1
Filing date	Oct 7, 2015
Priority date	Oct 17, 2014
Publication date	Aug 24, 2017
Grant date	—

Abstract

A porous carbon sheet contains a carbon fiber and a binding material, wherein layers are obtained in a section spanning from a plane closest to one of the surfaces and having 50% of the mean fluorine intensity to a plane closest to the other surface and having 50% of the mean fluorine intensity by dividing this section evenly into three in an orthogonal direction to the carbon sheet plane; among the layer close to one of the surfaces and the layer close to the other surface, the layer having the larger layer mean fluorine intensity is designated layer X, the layer having the smaller one is designated layer Y, and the layer between the layer X and the layer Y is designated layer Z; and the layer mean fluorine intensities decrease in the order: layer X, layer Y, and layer Z.

First claim

1 .- 10 . (canceled)

11 . A porous carbon sheet comprising a carbon fiber and a binding material, wherein
when among layers obtained by dividing the carbon sheet in a through-plane direction thereof into three equal parts within a section extending from a surface having a 50% average fluorine intensity, which is closest to one surface, to a surface having a 50% average fluorine intensity, which is closest to the other surface, one of a layer close to one surface and a layer close to the other layer, which has a larger average fluorine intensity, is a layer X, the other one of a layer close to one surface and a layer close to the other layer, which has a smaller average fluorine intensity, is a layer Y, and a layer between the layer X and the layer Y is a layer Z, the average fluorine intensity of the layer decreases in the order of the layer X, the layer Y and the layer Z.

12 . The carbon sheet according to claim 11 , wherein, when the average fluorine intensity of the layer Y is 1, the average fluorine intensity of the layer X is 1.30 to 9.00.

13 . The carbon sheet according to claim 11 , wherein, when the average fluorine intensity of the layer Y is 1, the average fluorine intensity of the layer Z is 0.10 to 0.90.

14 . The carbon sheet according to claim 11 , wherein a sliding angle of water at a surface Y is 40 degrees or less where the surface Y is a surface closest to the layer Y.

15 . The carbon sheet according to claim 11 , wherein the carbon sheet contains a hydrophobic material, and
the melting point of the hydrophobic material is 200 to 320° C.

16 . The carbon sheet according to claim 15 , wherein the hydrophobic material contains a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) and/or a tetrafluoroethylene-perfluoroalkylvinyl ether copolymer (PFA).

17 . The carbon sheet according to claim 11 , wherein the carbon sheet has a thickness of 50 to 230 μm.

18 . A gas diffusion electrode substrate, wherein when a surface closest to the layer X is a surface X, the gas diffusion electrode substrate has a microporous layer on the surface X side of the carbon sheet according to claim 11 .

19 . The gas diffusion electrode substrate according to claim 18 , wherein the microporous layer contains a carbon powder, and the carbon powder includes linear carbon having an aspect ratio of 30 to 5000.

20 . A fuel cell comprising the gas diffusion electrode substrate according to claim 18 .

21 . A fuel cell comprising the gas diffusion electrode substrate according to claim 19 .

22 . The carbon sheet according to claim 12 , wherein, when the average fluorine intensity of the layer Y is 1, the average fluorine intensity of the layer Z is 0.10 to 0.90.

23 . The carbon sheet according to claim 12 , wherein a sliding angle of water at a surface Y is 40 degrees or less where the surface Y is a surface closest to the layer Y.

24 . The carbon sheet according to claim 13 , wherein a sliding angle of water at a surface Y is 40 degrees or less where the surface Y is a surface closest to the layer Y.

25 . The carbon sheet according to claim 12 , wherein the carbon sheet contains a hydrophobic material, and
the melting point of the hydrophobic material is 200 to 320° C.

26 . The carbon sheet according to claim 13 , wherein the carbon sheet contains a hydrophobic material, and
the melting point of the hydrophobic material is 200 to 320° C.

27 . The carbon sheet according to claim 14 , wherein the carbon sheet contains a hydrophobic material, and
the melting point of the hydrophobic material is 200 to 320° C.

28 . The carbon sheet according to claim 12 , wherein the hydrophobic material contains a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) and/or a tetrafluoroethylene-perfluoroalkylvinyl ether copolymer (PFA).

29 . The carbon sheet according to claim 13 , wherein the hydrophobic material contains a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) and/or a tetrafluoroethylene-perfluoroalkylvinyl ether copolymer (PFA).

30 . The carbon sheet according to claim 14 , wherein the hydrophobic material contains a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) and/or a tetrafluoroethylene-perfluoroalkylvinyl ether copolymer (PFA).

Assignees

• Toray Industries

Inventors

• Utsunomiya Masamichi
• Hashimoto Masaru
• Sode Katsuya
• Kamae Toshiya

Classifications

• H01M4/8668

  Binders · CPC title

• H01M8/0245

  in the form of layered or coated products · CPC title

• H01M8/0234

  Carbonaceous material · CPC title

• H01M8/1007

  with both reactants being gaseous or vaporised (H01M8/12 takes precedence) · CPC title

• H01M4/8807

  Gas diffusion layers · CPC title