Porous electrode substrate and process for production thereof, porous electrode substrate precursor sheet, membrane-electrode assembly, and polymer electrolyte fuel cell

Patent metadata

Field	Value
Publication number	US-9325016-B2
Application number	US-201113882842-A
Country	US
Kind code	B2
Filing date	Oct 26, 2011
Priority date	Nov 1, 2010
Publication date	Apr 26, 2016
Grant date	Apr 26, 2016

Abstract

Provided are: a porous electrode substrate which has excellent handling properties and surface smoothness and satisfactory gas permeability and electrical conductivity, and enables the reduction of damage to a polymer electrolyte membrane when integrated into a fuel cell; and a process for producing the porous electrode substrate. Specifically provided are: a porous electrode substrate comprising a three-dimensional structure (Y- 1 ) produced by bonding short carbon fibers through carbon and a three-dimensional structure (Y- 2 ) produced by bonding short carbon fibers through carbon, wherein the three-dimensional structures (Y- 1 ) and (Y- 2 ) are layer stacked on and integrated with each other, the short carbon fibers form a three-dimensional entangled structure in the structure (Y- 1 ), and the short carbon fibers do not form a three-dimensional entangled structure in the structure (Y- 2 ); a process for producing the electrode base material; a precursor sheet for producing the electrode base material; a membrane-electrode assembly which involves the electrode base material; and a polymer electrolyte fuel cell.

First claim

The invention claimed is:

1. A porous electrode substrate, comprising:
a first structure comprising a plurality of first short carbon fibers, the first short carbon fibers bonded to each other by carbon such that the first structure is formed; and
a second structure comprising a plurality of second short carbon fibers, the second short carbon fibers bonded to each other by carbon such that the second structure is formed,
wherein
an average of angles formed by each of the first short carbon fibers and a surface of the first structure is 3° or more, or a maximum angle formed by each of the first short carbon fibers and the surface of the first structure is 10° or more, and
an average of angles formed by each of the second short carbon fibers and a surface of the second structure is less than 3° , and a maximum angle formed by each of the second short carbon fibers and the surface of the second structure is less than 10°.

2. The porous electrode substrate according to claim 1 ,
wherein
the first structure has a three-dimensional structure in which the first short carbon fibers are bonded by three-dimensional mesh-like carbon fibers, and
the second structure has a three-dimensional structure in which the second short carbon fibers are bonded by two-dimensional mesh-like carbon fibers.

3. A porous electrode substrate precursor sheet, comprising:
a first precursor sheet comprising a plurality of first short carbon fibers dispersed in the first precursor sheet, and at least one of a first short carbon fiber precursor and a first fibrillar carbon fiber precursor; and
a second precursor sheet comprising a plurality of second short carbon fibers dispersed in the second precursor sheet, and at least one of a second short carbon fiber precursor and a second fibrillar carbon fiber precursor,
wherein
an average of angles formed by each of the first short carbon fibers and a surface of the first precursor sheet is 3° or more, or a maximum angle formed by each of the first short carbon fibers and the surface of the first precursor sheet is 10° or more, and
an average of angles formed by each of the second short carbon fibers and a surface of the second precursor sheet is less than 3° , and a maximum angle formed by each of the second short carbon fibers and the surface of the second precursor sheet is less than 10°.

4. The porous electrode substrate precursor sheet according to claim 3 ,
wherein
a mass ratio of the first short carbon fibers to a total of the first short carbon fiber precursor and the first fibrillar carbon fiber precursor is from 20:80 to 80:20, and
a mass ratio of the second short carbon fibers to a total of the second short carbon fiber precursor and the second fibrillar carbon fiber precursor is from 20:80 to 80:20.

5. A membrane-electrode assemblyl, comprising:
the porous electrode substrate according to claim 1 .

6. A polymer electrolyte fuel cell, comprising:
the membrane-electrode assembly according to claim 5 .

7. The porous electrode substrate according to claim 1 ,
wherein the first structure is stacked on the second structure such that the first and second structures form an integrated structure.

8. The porous electrode substrate precursor sheet according to claim 3 ,
wherein the first precursor sheet is stacked on the second precursor sheet such that the first and second precursor sheets form an integrated structure.

9. The porous electrode substrate according to claim 2 ,
wherein an average of angles formed by each of the three-dimensional mesh-like carbon fibers and a surface of the first structure is 3° or more, and
an average of angles formed by each of the second-dimensional mesh-like carbon fibers and a surface of the second structure is less than 2°.

10. The porous electrode substrate according to claim 2 ,
wherein a total content of the three-dimensional mesh-like carbon fibers and two-dimensional mesh-like carbon fibers is from 5 to 90% by mass.

11. The porous electrode substrate according to claim 1 , wherein the porous electrode substrate has a basis weight of from 15 to 100 g/m 2 .

12. The porous electrode substrate according to claim 1 , wherein the porous electrode substrate has a thickness of from 50 to 300 μm.

13. The porous electrode substrate according to claim 3 , wherein the porous electrode substrate precursor sheet has a thickness of from 20 to 400 μm.

Assignees

• Sumioka Kazuhiro
• Sako Yoshihiro
• Mitsubishi Rayon Co

Inventors

• Sumioka Kazuhiro
• Sako Yoshihiro

Classifications

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M4/8875

  Methods for shaping the electrode into free-standing bodies, like sheets, films or grids, e.g. moulding, hot-pressing, casting without support, extrusion without support · CPC title

• H01M8/0245

  in the form of layered or coated products · CPC title

• H01M4/8657 Primary

  layered · CPC title

• H01M4/8626

  characterised by the form · CPC title