Conductive porous layer for batteries and fabrication method for same

Patent metadata

Field	Value
Publication number	US-9666872-B2
Application number	US-201615090958-A
Country	US
Kind code	B2
Filing date	Apr 5, 2016
Priority date	Mar 25, 2011
Publication date	May 30, 2017
Grant date	May 30, 2017

Abstract

The conductive porous layer for batteries according to the present invention comprises a laminate comprising a first conductive layer and a second conductive layer. The first conductive layer includes at least a conductive carbon material and a polymer. The second conductive layer includes at least a conductive carbon material and a polymer. The conductive porous layer satisfies at least one of the following two conditions: “the polymer in the first conductive layer is present with a high density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer” and “the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer.” This makes it possible to provide a conductive porous layer with good adhesion between the first conductive layer and the second conductive layer and with reduced film thickness variation in each conductive layer. The conductive porous layer of the present invention can be used for fuel cells, metal-air batteries, and the like.

First claim

The invention claimed is:

1. A membrane-electrode assembly for batteries wherein a conductive porous layer is laminated on one side or both sides of a catalyst layer laminated membrane comprising a catalyst layer, an electrolyte membrane, and a catalyst layer that are sequentially laminated, the conductive porous layer comprising a laminate comprising a first conductive layer and a second conductive layer,
wherein the conductive porous layer is laminated on one or both sides of the catalyst layer laminated membrane in such a manner that the first conductive layer is in contact with the catalyst layer;
the first conductive layer comprising at least a conductive carbon material and a polymer,
the second conductive layer comprising at least a conductive carbon material and a polymer,
the first conductive layer and the second conductive layer being porous, and
the conductive porous layer satisfying at least one of the following conditions:
(A) the polymer in the first conductive layer is present with a higher density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer, and
(B) the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer.

2. The membrane-electrode assembly for batteries according to claim 1 , wherein the glass transition temperature of the polymer in the first conductive layer is −100 to 300° C., and/or the glass transition temperature of the polymer in the second conductive layer is −100 to 300° C.

3. The membrane-electrode assembly for batteries according to claim 1 , wherein the glass transition temperature of the polymer in the second conductive layer is −100 to 300° C.

4. The membrane-electrode assembly for batteries according to claim 1 that satisfies both of the above conditions (A) and (B).

5. The membrane-electrode assembly for batteries according to claim 1 wherein the conductive carbon material in the second conductive layer is conductive carbon fibers with an average fiber diameter of 5 μm or more and/or conductive carbon particles with an average particle diameter of 5 μm or more.

6. The membrane-electrode assembly for batteries according to claim 1 , wherein the conductive porous layer is a gas diffusion layer for fuel cells or a conductive porous layer for metal-air batteries.

7. A battery comprising the membrane-electrode assembly for batteries according to claim 1 .

8. The membrane-electrode assembly for batteries according to claim 1 , wherein the first conductive layer and the second conductive layer are laminated in such a manner as to satisfy one of the following conditions:
(a) the polymer in the first conductive layer is present with a higher density at the surface of the layer not in contact with the second conductive layer than at the surface of the layer in contact with the second conductive layer, and the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer;
(b) the polymer in the first conductive layer is present with a higher density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer, and the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer; and
(c) the polymer in the first conductive layer is present with a higher density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer, and the polymer in the second conductive layer is present with a higher density at the surface of the layer not in contact with the first conductive layer than at the surface in contact with the first conductive layer.

9. The membrane-electrode assembly for batteries according to claim 1 , further comprising a conductive porous substrate on the second conductive layer.

10. A laminate for batteries wherein a conductive porous layer is laminated on a catalyst layer, the conductive porous layer comprising a laminate comprising a first conductive layer and a second conductive layer,
wherein the conductive porous layer is laminated on one or both sides of the catalyst layer laminated membrane in such a manner that the first conductive layer is in contact with the catalyst layer,
the first conductive layer comprising at least a conductive carbon material and a polymer,
the second conductive layer comprising at least a conductive carbon material and a polymer,
the first conductive layer and the second conductive layer being porous, and
the conductive porous layer satisfying at least one of the following conditions:
(A) the polymer in the first conductive layer is present with a higher density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer, and
(B) the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer.

11. A laminate for batteries wherein a conductive porous layer is stacked on a separator, the conductive porous layer comprising a laminate comprising a first conductive layer and a second conductive layer,
the first conductive layer comprising at least a conductive carbon material and a polymer,
the second conductive layer comprising at least a conductive carbon material and a polymer,
the first conductive layer and the second conductive layer being porous, and
the conductive porous layer satisfying at least one of the following conditions:
(A) the polymer in the first conductive layer is present with a higher density at the surface of the layer in contact with the second conductive layer than at the surface not in contact with the second conductive layer, and
(b) the polymer in the second conductive layer is present with a higher density at the surface of the layer in contact with the first conductive layer than at the surface not in contact with the first conductive layer.

Assignees

• Dainippon Printing Co Ltd

Inventors

• Takeuchi Naoya
• Kishimoto Hiroshi
• Oi Kasumi

Classifications

• Y02P70/50

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

• Y02P70/56

  Cross-Sectional Technologies · mapped topic

• H01M8/0239

  Organic resins; Organic polymers · CPC title

• H01M8/0234

  Carbonaceous material · CPC title

• H01M4/8673

  Electrically conductive fillers · CPC title