Mesoporous carbon, electrode catalyst for fuel cell, catalyst layer, fuel cell, and method for producing mesoporous carbon

Patent metadata

Field	Value
Publication number	US-2022320528-A1
Application number	US-202217656797-A
Country	US
Kind code	A1
Filing date	Mar 28, 2022
Priority date	Mar 30, 2021
Publication date	Oct 6, 2022
Grant date	—

Abstract

Mesoporous carbon has a connecting structure in which primary particles made of carbon particles having primary pores with a primary pore diameter of less than 20 nm are connected. In the mesoporous carbon, the pore capacity of secondary pores with secondary pore diameters within a range of 20 nm to 100 nm, which is measured by a mercury intrusion method, is 0.42 cm 3 /g or more and 1.34 cm 3 /g or less. In addition, the mesoporous carbon has a linearity of 2.2 or more and 2.6 or less. An electrode catalyst for a fuel cell includes the mesoporous carbon and catalyst particles supported in the primary pores in the mesoporous carbon. Furthermore, a catalyst layer includes the electrode catalyst for the fuel cell and a catalyst layer ionomer.

First claim

What is claimed is:

1 . Mesoporous carbon, wherein the mesoporous carbon has
a connecting structure in which primary particles made of carbon particles having primary pores with a primary pore diameter of less than 20 nm are connected, a pore capacity of secondary pores with a secondary pore diameter within a range of 20 nm to 100 nm, which is measured by a mercury intrusion method, and which is 0.42 cm 3 /g or more and 1.34 cm 3 /g or less, and a linearity of 2.2 or more and 2.6 or less.

2 . The mesoporous carbon according to claim 1 , wherein an average particle diameter of the primary particles is 30 nm or more and 300 nm or less.

3 . The mesoporous carbon according to claim 1 , wherein the pore capacity of the secondary pores is 0.42 cm 3 /g or more and 1.00 cm 3 /g or less.

4 . An electrode catalyst for a fuel cell comprising:
the mesoporous carbon according to claim 1 ; and catalyst particles supported in the primary pores of the mesoporous carbon.

5 . A catalyst layer comprising:
the electrode catalyst for the fuel cell according to claim 4 ; and a catalyst layer ionomer.

6 . The catalyst layer according to claim 5 , wherein the catalyst layer is an air electrode catalyst layer of the fuel cell.

7 . A fuel cell comprising the catalyst layer according to claim 5 .

8 . A method for producing mesoporous carbon comprising:
a first step of preparing mesoporous silica that is a template; a second step of precipitating carbon in mesopores of the mesoporous silica to produce a mesoporous silica and carbon complex; and a third step of removing the mesoporous silica from the complex.

9 . The method according to claim 8 , further comprising a fourth step of thermally treating the mesoporous carbon at a temperature higher than 1500° C. after the third step.

10 . The method according to claim 8 , wherein the first step includes
a polymerizing step of performing condensation polymerization of a silica source in a reaction solution containing the silica source, a surfactant, and a catalyst, to obtain precursor particles, a drying step of separating the precursor particles from the reaction solution and drying the precursor particles, and a firing step of firing the precursor particles to obtain the mesoporous silica.

11 . The method according to claim 10 , wherein the first step further includes a diameter expansion step of performing a diameter expansion treatment on the dried precursor particles.

Assignees

• Toyota Motor Co Ltd

Inventors

• Hasegawa Naoki
• Yano Kazuhisa
• Takeshita Tomohiro
• Imoto Rui
• Nomura Kumiko
• Kitao Noriyuki
• Wang Yunan
• Kasama Yuuki

Classifications

• H01M8/1018

  Polymeric electrolyte materials · CPC title

• H01M4/9083 Primary

  on carbon or graphite · CPC title

• H01M2008/1095

  Fuel cells with polymeric electrolytes · CPC title

• C01B32/205

  Preparation · CPC title

• H01M4/926 Primary

  on carbon or graphite · CPC title