Catalyst coating film for gas reactions and method for producing the same

Abstract

The present invention provides a method for manufacturing a catalyst coating film and a catalyst coating film that have high surface flatness and high uniformity, thereby significantly improving the yield of the catalyst coating film process and reducing costs. [Solution] The steps are: preparing a first substrate having a first surface; forming a first catalyst layer on the first surface of the first substrate; preparing a second substrate having a friction coefficient in the range of 2 to 15 on the first catalyst layer; and forming the catalyst coating film with a friction coefficient of 0 kgf / cm². 2 Exceeding 380 kgf / cm² 2 The process includes the step of pressurizing and laminating the first catalyst layer onto the second substrate by applying pressure to a film within the following range.

Description

[Technical Field]

[0001] The present invention relates to a catalyst coating film for gas reactions and a method for producing the same, and more particularly to a catalyst coating film including a high friction coefficient substrate and a method for producing the same. [Background technology]

[0002] Catalyst-coated membranes (CCMs) can accelerate the generation of electrochemical reactions and are currently widely used in technological fields such as hydrogen and oxygen production through water electrolysis, carbon dioxide reduction, gas sensors, and fuel cells. Currently, the main methods for manufacturing CCMs are direct coating and transfer printing.

[0003] The transfer printing method involves coating a catalyst slurry onto the surface of a transfer medium, heating it to remove the solvent and form a catalyst layer, and then transferring the catalyst layer to a proton exchange membrane using heat and pressure. However, the transfer printing method has drawbacks such as complex steps, high preparation costs, and high manufacturing costs. During the heat and pressure transfer, it is difficult to control the contact between the catalyst layer and the membrane, resulting in uneven stress at the contact edges between the membrane and the transfer medium, which can easily damage the membrane. During the transfer step, the transfer is incomplete, causing some of the catalyst to adhere to the transfer medium, reducing the catalyst utilization rate. The transfer medium is easily damaged by repeated heat and pressure and cannot be reused, thus increasing manufacturing costs.

[0004] The direct coating method involves preparing a catalyst slurry using a large amount of solvent and directly coating it onto a proton exchange membrane, resulting in improved performance due to the close adhesion between the catalyst layer and the proton exchange membrane. Compared to the transfer printing method, the direct coating method has simpler steps and improves the performance of the manufactured CCM because it allows for close adhesion between the catalyst layer and the proton exchange membrane. However, because the proton exchange membrane coated with the catalyst slurry is very thin and flexible (for example, Nafion 212 and Nafion 211 have thicknesses of approximately 50 microns and 25 microns, respectively), it is difficult to flatten and fix the proton exchange membrane during the catalyst slurry coating process. Existing techniques typically involve placing the membrane flat on a flat substrate and manually applying the catalyst with a brush; this method is not very efficient. Other more efficient direct coating methods (such as roll-to-roll (R2R) coating) typically use suction to fix the proton exchange membrane during the coating process to firmly fix it in place. For example, the proton exchange membrane is firmly adsorbed onto the stage surface under negative pressure (or vacuum) through multiple suction holes on the stage. Sufficient negative pressure (vacuum) suction is necessary to prevent the proton exchange membrane from moving during direct coating, but very thin membranes are prone to wrinkling and deformation. Furthermore, proton exchange membranes swell and deform easily when exposed to moisture or alcohol-based solvents. Severe deformation can cause the catalyst layer around the deformed area to peel off, reducing the catalyst's utilization rate and performance. Since catalyst slurries typically contain solvents such as water or ethanol, direct coating often results in uneven film formation, making it difficult to obtain a uniform CCM. To overcome this problem, the first and second side catalyst layers can be manufactured by direct coating and transfer printing, respectively, or a solvent removal step can be added to the process. However, these methods complicate the manufacturing process and reduce production efficiency.

[0005] Based on the above, surface irregularities and film deformation issues in CCMs are major obstacles to CCM manufacturing methods, and there is a need in this field for CCMs and manufacturing methods that can overcome these problems.

[0006] The applicant of this application, taking into consideration the shortcomings of the prior art, and through careful experimentation, research, and persistent effort, has finally invented the present invention, "Catalyst Coating Film for Gas Reactions and Method for Producing the Same," which overcomes the shortcomings of the prior art. The present invention is briefly described below. [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] The object of this application is to provide a CCM and a method for manufacturing the same that can solve the problems of surface irregularities and film deformation of CCM. This method enables the production of CCM with high efficiency and avoids problems such as deformation, swelling, detachment of the catalyst layer, and cracking of the catalyst layer of the produced CCM. In other words, the CCM produced by the method of this application has high surface flatness and high uniformity, thereby significantly improving the yield of the CCM process and reducing costs. [Means for solving the problem]

[0008] One of the objectives of this application is to provide a method for manufacturing a catalyst coating film for gas reactions. The method comprises the steps of: preparing a first substrate having a first surface; forming a first catalyst layer on the first surface of the first substrate; preparing a second substrate having a coefficient of friction in the range of 2 to 15 on the first catalyst layer; and forming the catalyst coating film with a friction coefficient of 0 kgf / cm². 2 Exceeding 380 kgf / cm² 2 The process includes the step of pressurizing and laminating the first catalyst layer onto the second substrate by applying pressure to a film within the following range.

[0009] Another objective of this application is to provide a method for manufacturing a catalyst coating film for gas reactions. The method comprises the steps of preparing a sandwich structure including a first substrate, a second substrate having a friction coefficient in the range of 2 to 15, and a catalyst layer sandwiched between the first and second substrates, and 0 kgf / cm 2 Exceeding 380 kgf / cm² 2The step of pressurizing and stacking the sandwich structure at a pressure within the following range is included.

[0010] Another object of this application is to provide a method for manufacturing a catalyst coating film for gas reactions. The method includes the steps of: preparing a substrate having a first surface, a second surface, and a first protective film and a second protective film that protect the first surface and the second surface, respectively; removing the first protective film; coating the first surface with a first catalyst layer; covering the first catalyst layer with a protective layer and replacing the first protective film; removing the second protective film; and coating the second surface with a second catalyst layer.

[0011] Another objective of this application is to provide a catalyst coating film for gas reactions. The catalyst coating film for gas reactions comprises a first substrate, a second substrate having a coefficient of friction in the range of 2 to 15 and comprising at least one material of silicone, rubber, silicone rubber, and polymer, and a catalyst layer sandwiched between the first substrate and the second substrate.

[0012] The above embodiments and advantages of the present invention will become more readily apparent to those skilled in the art after reviewing the following detailed description and accompanying drawings. [Brief explanation of the drawing]

[0013] [Figure 1] A flowchart shows a method for producing a catalyst coating film (CCM) for gas reactions according to an embodiment of the present invention. [Figure 2A] This shows a single-sided CCM manufactured according to the manufacturing method according to an embodiment of the present invention. [Figure 2B] This shows a double-sided CCM manufactured according to the manufacturing method according to an embodiment of the present invention. [Figure 3] This figure shows the effect of different static friction coefficients of the second substrate samples 1-5 in Examples 1-5 on the CCM surface flatness. [Modes for carrying out the invention]

[0014] When reading the following detailed description, refer to all the figures of the present invention. All the figures of the present invention show different embodiments of the present invention by way of example and are helpful for those skilled in the art to understand how to implement the present invention. This embodiment provides sufficient embodiments to demonstrate the spirit of the present invention. Each embodiment does not conflict with other embodiments, and new embodiments can be implemented through any combination thereof. That is, the present invention is not limited to the embodiments disclosed herein.

[0015] Unless otherwise specifically limited or described in a specific example, the following definitions apply to the terms used throughout this specification.

[0016] As used herein, the term "comprising" or "including" means that the presence of one or more other components, steps, and / or elements is not excluded in addition to the described components, steps, and / or elements.

[0017] As used herein, the term "about" means having a close or acceptable error range to prevent the present invention from being limited to the exact or absolute numerical values disclosed. The term "one" used herein means that the grammatical purpose of the article is one or more.

[0018] As used herein, the term "single-sided CCM" or "single-sided catalyst-coated membrane" refers to that only one of the two opposing surfaces of the catalyst-coated membrane (CCM) manufactured by the single-sided coating method is covered with a catalyst layer.

[0019] As used herein, the term "double-sided CCM" or "double-sided catalyst-coated membrane" refers to a double-sided catalyst-coated membrane (CCM) manufactured by double-sided coating, in which both sides of the CCM are covered with a catalyst layer.

[0020] Figure 1 shows a flowchart of a method for producing a catalyst coating film (CCM) for gas reactions according to an embodiment of the present invention. As shown in Figure 1, this method includes the following steps.

[0021] Step S1: A first substrate having opposing first and second surfaces is prepared. In some specific embodiments, the first substrate is a polymer film such as a perfluorosulfonic acid polymer film. In some specific embodiments, the first substrate is an electrolyte membrane (or proton exchange membrane or ion exchange membrane) such as a cation exchange membrane, an anion exchange membrane, a perfluorosulfonic acid ion exchange membrane, Nafion 212, Nafion 117, Nafion 119, or Nafion 211. Each of the above model numbers differs in the thickness of the electrolyte membrane, with Nafion 212 being an example, having a thickness of approximately 50.8 microns. Considering the very thin thickness of the first substrate, in some embodiments, the first substrate has a first protective film (also called a cover film) and a second protective film (also called a bottom film) that protect the first surface and the second surface, respectively. The cover film and bottom film may be, for example, thin plastic films, and when the cover film is removed, the first surface of the first substrate is exposed, and when the bottom film is removed, the second surface of the first substrate is exposed.

[0022] Step S2: A first catalyst layer is formed on the first surface of the first substrate. In some specific embodiments, the first catalyst layer is formed by direct coating. "Direct coating" means that the first catalyst layer is directly coated or formed on the first surface, and not formed elsewhere by, for example, a transfer printing method and then transferred to the first surface of the first substrate. In some specific embodiments, methods for forming the first catalyst layer include, but are not limited to, roll-to-roll (R2R) coating, brush coating, ultrasonic coating, blade coating, transfer printing, or screen printing. In certain embodiments where the first substrate has a cover film and a bottom film, step S2 includes removing the cover film from the first surface to expose the first surface of the first substrate and forming the first catalyst layer on the first surface. Although the thickness of the first substrate is extremely thin, the bottom can support and fix the first substrate with its first surface exposed, so that the first substrate is less likely to deform, crease, or swell during step S2, and the shape of the formed substrate is also good, and the formed first catalyst layer has a smooth surface without creases. The thickness range of the first catalyst layer varies depending on the method of forming the first catalyst layer, but for example, when using the blade coating method, the thickness of the formed first catalyst layer is preferably about 15 to 80 μm.

[0023] In some specific embodiments, step S2 specifically includes heating a first substrate to a coating temperature, supplying a first catalyst layer slurry onto a first surface of the first substrate at the coating temperature to form a first catalyst layer on the first surface, and drying the formed first catalyst layer. During the coating process, the temperature is first raised to the coating temperature before the first catalyst layer is coated, thereby flattening the surface of the first catalyst layer. The first catalyst layer slurry may contain about 20% to 70% by weight of catalyst, an appropriate amount of binder, and an appropriate amount of dispersant. The catalyst includes at least one of Pt, Ru, Ir, Au, Ni, Co, Zn, Ag, and their alloys or oxides. For example, the catalyst material in the first catalyst layer may include Pt / C, PtRu / C, Ru / C, IrO2, or other noble metals and metal oxides. Examples of binders include perfluorosulfonic acid resins. The dispersant may be water or at least one of alcohols, such as methanol, ethanol, isopropyl alcohol, n-propanol, and n-butanol. The temperature used to dry the first catalyst layer depends on the composition of the first catalyst layer; for example, the drying temperature can be approximately 70°C to 150°C.

[0024] Step S3: Prepare a second substrate having a coefficient of friction in the range of 2 to 15 on the first catalyst layer. This coefficient of friction is the static coefficient of friction defined based on the international standard ASTM D1894. In the ASTM D1894 standard specification, it is intended to test the dynamic and static frictional forces generated between the overlapping films (second substrate) during the drag process, and the dynamic and static coefficients of friction of the film (second substrate) can be known from the calculation results. Preferably, the second substrate has a coefficient of friction in the range of 5 to 15, and more preferably, the coefficient of friction is in the range of 10 to 15. In some specific embodiments, the second substrate includes at least one of the materials of silicone, rubber, silicone rubber, and polymer. Preferably, the second substrate includes at least one of the materials of silicone, rubber, and silicone rubber. According to the experiments of the present invention, it has been confirmed that the coefficient of friction of the second substrate has a positive correlation with the flatness of the manufactured CCM. Therefore, the material of the second substrate in the embodiments of the present invention includes any material having a coefficient of friction in the range of 5 to 15, and is not limited to the materials explicitly listed above.

[0025] Step S4: A pressure on the film exceeding 0 Kgf / cm 2 and not exceeding 380 Kgf / cm 2 is applied to press and laminate the first catalyst layer onto the second substrate to form a single-sided CCM. The pressure on the film preferably exceeds 0 kgf / cm 2 and does not exceed 50 kgf / cm 2 More preferably, the pressure on the film exceeds 0 kgf / cm 2 and does not exceed 10 kgf / cm 2 The above pressing and lamination can be performed in an atmospheric environment or a vacuum environment, and if necessary, a thermal pressing and lamination process or a normal temperature pressing and lamination process can be performed. In this step, the extremely thin first substrate is adhered to the second substrate with a high coefficient of friction by the pressing and lamination force. Thereby, the non-uniform surface swelling effect generated when the CCM is manufactured by a direct coating process can be solved. The single-sided CCM manufactured in this way has a flat surface of the first substrate and the first catalyst layer, and there is no swelling, crease, or deformation.

[0026] When manufacturing a single-sided CCM, the process ends after step S4. When manufacturing a double-sided CCM, step S5 is executed after step S4.

[0027] Step S5: A second catalyst layer is formed on the second surface of the first substrate to form a double-sided CCM. In some specific embodiments, the formation of the second catalyst layer is carried out by direct coating. "Direct coating" means that the second catalyst layer is directly coated or formed on the second surface, and not formed elsewhere by, for example, a transfer printing method and then transferred to the second surface. In some specific embodiments, methods for forming the second catalyst layer include, but are not limited to, roll-to-roll (R2R) coating, brush coating, ultrasonic coating, blade coating, transfer printing, or screen printing. In certain embodiments where the first substrate has a cover film and a bottom film, step S5 includes removing the bottom film on the second surface to expose the second surface of the first substrate. The thickness of the first substrate is extremely thin, but the second substrate, having a specific coefficient of friction range, can support and adhere to the first substrate with its second surface exposed, so that the first substrate does not easily deform, move, or shrink during step S5, and the first substrate becomes flat when the second catalyst is applied, ensuring that the formed second catalyst layer has a flat surface without swelling or creases. The thickness range of the second catalyst layer varies depending on the method of forming the second catalyst layer, but for example, when using the blade coating method, the thickness of the formed second catalyst layer is preferably about 15 to 80 μm. In some specific embodiments, the thickness of the second catalyst layer is the same as the thickness of the first catalyst layer. In some specific embodiments, the thickness of the second catalyst layer is different from the thickness of the first catalyst layer.

[0028] In some specific embodiments, step S5 specifically includes heating the first substrate to a coating temperature, supplying a second catalyst layer slurry onto the second surface of the first substrate at the coating temperature to form a second catalyst layer on the second surface, and drying the formed second catalyst layer. During the coating process, the temperature first rises to the coating temperature before the second catalyst layer is coated, thereby flattening the surface of the second catalyst layer or CCM. The second catalyst layer slurry may contain about 20% to 70% by weight of catalyst, an appropriate amount of binder, and an appropriate amount of dispersant. The catalyst includes at least one of Pt, Ru, Ir, Au, Ni, Co, Zn, Ag, and their alloys or oxides. For example, the catalyst material in the second catalyst layer may include Pt / C, PtRu / C, Ru / C, IrO2, or other noble metals and metal oxides. Examples of binders include perfluorosulfonic acid resins. The dispersant may be water or at least one of alcohols, such as methanol, ethanol, isopropyl alcohol, n-propanol, and n-butanol. The temperature used to dry the second catalyst layer depends on the composition of the second catalyst layer; for example, the drying temperature may be about 70°C to 150°C.

[0029] In some specific embodiments, a catalyst coating method for gas reactions includes the following steps: First, a substrate (e.g., an electrolyte film or a polymer film) is prepared. This substrate has opposing first and second surfaces, and first and second protective films (e.g., the aforementioned cover film or bottom film) that protect the first and second surfaces, respectively. Next, the first protective film (e.g., the aforementioned cover film) is removed, and a first catalyst layer is coated (e.g., directly coated) onto the first surface of the substrate. Then, a new protective layer (e.g., the aforementioned second substrate) is applied over the first catalyst layer in place of the first protective film to form a single-sided CCM. The new protective layer has a coefficient of friction in the range of 2 to 15, preferably 5 to 15, more preferably 10 to 15, to support and protect the substrate. The aforementioned coefficient of friction preferably refers to the ASTM D1894 static coefficient of friction. Then, the second protective film (e.g., the aforementioned bottom film) is removed, and a second catalyst layer is coated onto the second surface of the substrate to form a double-sided CCM. The present invention, through the existence of a new protective layer having a specific coefficient of friction range, overcomes the drawbacks of conventional direct coating methods in CCM manufacturing processes, such as the tendency for deformation and surface swelling of the electrolyte membrane due to contact with a large amount of solvent. It does not require the addition of new steps, and does not require the addition of other steps (additional solvent removal procedures) or equipment (e.g., vacuum suction devices) to use the direct coating method, thus achieving superior CCM performance and a simpler process. Furthermore, the present invention can also be applied to indirect coating methods (such as transfer printing), enabling the production of CCM with a flat surface and no swelling.

[0030] Referring to Figures 2A and 2B, these show single-sided and double-sided CCMs manufactured according to the flowchart in Figure 1. As shown in Figures 2A and 2B, both single-sided and double-sided CCMs include the sandwich structure shown in Figure 2A. The sandwich structure includes a first substrate 21, a second substrate 22 having a coefficient of friction in the range of 2 to 15, preferably 5 to 15, more preferably 10 to 15, and a first catalyst layer 23 sandwiched between the first substrate 21 and the second substrate 22. Preferably, the second substrate 22 includes at least one material from silicone, rubber, silicone rubber, and polymer. Preferably, the sandwich structure is a structure that is laminated by pressurizing the film. As shown in Figure 2B, the double-sided CCM also includes a second catalyst layer 24 on the surface of the first substrate 21 in addition to the sandwich structure. In the example shown in Figure 2B, the first catalyst layer 23 and the second catalyst layer 24 have the same composition, but in other embodiments, the first catalyst layer 23 and the second catalyst layer 24 may have different compositions.

[0031] In some specific embodiments, a catalyst coating method for gas reactions includes the following steps. First, a sandwich structure is prepared. This sandwich structure includes a first substrate, a second substrate having a coefficient of friction in the range of 2 to 15, preferably 5 to 15, more preferably 10 to 15, and a catalyst layer sandwiched between the first substrate 21 and the second substrate 22. For example, the sandwich structure can be prepared by the method described in steps S1 to S3 of Figure 1. Next, the sandwich structure is subjected to 0 kgf / cm 2 Exceeding 380 kgf / cm² 2 The layers are laminated under pressure within the following range. The pressure is preferably 0 kgf / cm². 2 Exceeding 50 kgf / cm² 2 It is within the following range, and more preferably 0 kgf / cm² 2 Exceeding 10 kgf / cm² 2 It is within the following range. Next, the other catalyst layer is placed on the surface of the first substrate such that the catalyst layer and the other catalyst layer are each placed on two opposing surfaces of the first substrate.

[0032] Example 1 This embodiment presents a method for manufacturing a CCM according to the present invention, which combines blade coating and direct coating techniques, and mainly includes a first catalyst layer coating process, a pressure lamination process, and a second catalyst layer coating process. These are described below.

[0033] First, prepare the first catalyst slurry and the second catalyst slurry according to the material ratios shown in Table 1.

[0034] [Table 1]

[0035] First catalyst layer coating process A first substrate (electrolyte membrane Nafion 212) equipped with a cover film and a bottom film was spread out, and the cover film was peeled off to expose the first surface of the electrolyte membrane. At this time, the bottom film still covered the second surface of the electrolyte membrane. The first surface of the first substrate was covered with a 0.1 mm thick blade coating mold, heated to a coating temperature of 70°C, and blade coating was directly performed on the first surface of the electrolyte membrane using a 0.5 cc first catalyst slurry titration, a blade spacing of 0.1 mm, and a blade coating speed of 1 mm / second, forming a first catalyst layer on the first surface measuring 2.5 cm × 2.5 cm and 30 μm thick. Next, the first catalyst layer was dried at a temperature of 70°C to at least partially evaporate the solvent in the first catalyst layer. After drying, the surface of the first catalyst layer was flat, and no swelling or deformation of the electrolyte membrane was observed.

[0036] Pressurized lamination process The first catalyst layer was placed on the second substrate (a silicone film with an ASTM D1894 static friction coefficient of 13.78) at room temperature and under a pressure of 0.288 kgf / cm². 2 A single-sided CCM was manufactured by pressurizing and laminating the film under the following conditions: pressure on the film, weight 1.8 kg, air pressure 760 torr, and pressurized lamination time 30 minutes. Upon observation, the surface of the single-sided CCM after pressurized lamination was flat and showed no swelling or deformation.

[0037] Second catalyst layer coating process After removing the bottom film, the second surface of the electrolyte membrane was exposed. The second surface of the electrolyte membrane was covered with a 0.1 mm thick blade coating mold, heated to a coating temperature of 70°C, and directly blade coating was performed on the second surface of the electrolyte membrane using a 0.5 cc second catalyst slurry titration, a blade spacing of 0.1 mm, and a blade coating speed of 1 mm / second, forming a second catalyst layer measuring 2.5 cm × 2.5 cm and 30 μm thick on the second surface. Next, the second catalyst layer was dried at a temperature of 70°C to at least partially evaporate the solvent in the second catalyst layer, and finally, the prepared double-sided CCM was rolled up. The surfaces of the dried second catalyst layer and double-sided CCM were flat, and no swelling or deformation was observed.

[0038] Example 2 This embodiment is based on the manufacturing method of the present invention and uses a second substrate having a different coefficient of friction to manufacture the double-sided CCMs of Examples 1 to 5. This manufacturing method combines blade coating with direct coating technology and mainly includes a first catalyst layer coating process, a pressure lamination process, and a second catalyst layer coating process.

[0039] First, prepare the first catalyst slurry and the second catalyst slurry according to the material ratios shown in Table 2.

[0040] [Table 2]

[0041] The first catalyst layer coating process was carried out in the same manner as in Example 1. After drying, the surface of the first catalyst layer was flat, and no swelling or deformation of the electrolyte membrane was observed.

[0042] Pressurized lamination process The first catalyst layer was placed on the second substrate (silicone film samples 1-5 with ASTM D1894 static friction coefficients as defined in Table 3) at room temperature and a pressure of 1.288 kgf / cm². 2A single-sided CCM was manufactured by pressurizing and laminating the film under the following conditions: pressure on the film, weight 1.8 kg, air pressure 760 torr, and pressurized lamination time 30 minutes. Upon observation, the surface of the single-sided CCM after pressurized lamination was flat and showed no swelling or deformation.

[0043] The second catalyst layer coating process was carried out in the same manner as in Example 1. The overall surface condition of the manufactured double-sided CCM was observed and is shown in Table 3.

[0044] [Table 3]

[0045] Referring to Figure 3, which shows the effect of different static friction coefficients of second substrate samples 1-5 in Examples 1-5 on the surface flatness of the CCM. As shown in Figure 3, the larger the static friction coefficient of the second substrate, the better the surface flatness of the manufactured double-sided CCM, and a clear positive correlation was observed between the two. In particular, when the static friction coefficient of the second substrate was less than 2 (for example, second substrate samples 1 and 2 in Examples 1 and 2 of Table 3), double-sided CCMs manufactured using such second substrates had clear problems of surface swelling and bulging.

[0046] Example 3 This example is based on the manufacturing method of the present invention and produced double-sided CCMs Examples 6-9 with different catalyst layer thicknesses. The manufacturing method mainly includes a first catalyst layer coating process, a pressure lamination process, and a second catalyst layer coating process, similar to Example 1. The difference between this example and Example 1 is that this example produced double-sided CCMs with first / second catalyst layers of different thicknesses using molds of different thicknesses, as defined in Table 4. The overall surface condition of the produced double-sided CCMs is also described in Table 4. As shown in Table 4, the thickness of the coated catalyst layer increases as the thickness of the mold increases. Examples 6-9 used molds with thicknesses of 100-400 μm, respectively. Increasing the thickness of the coating layer requires a larger amount of catalyst layer slurry to be supplied to the electrolyte membrane, which inevitably increases the amount of the electrolyte membrane exposed to the coating solvent at one time. From the surface condition results in Table 4, it was found that even with thick catalyst layers of 61 μm and 76.3 μm (see Example 9), no surface defects occurred on the CCM surface. Therefore, the method of the present invention does not cause wrinkles or swelling on the surface of the CCM due to an increase in the amount of solvent applied in a single coating.

[0047] [Table 4]

[0048] The method of the present invention can solve two major problems: the difficulty of planarizing and fixing the substrate when forming the catalyst layer of a CCM, and the swelling effect caused by contact with a large amount of solvent on the substrate. In the present invention, by performing coating at a coating temperature higher than room temperature in the manufacturing process, the surface of the formed catalyst layer becomes flat. Furthermore, since the present invention manufactures a CCM using a second substrate with a high coefficient of friction, a very thin first substrate can be adsorbed and fixed using the second substrate with a high coefficient of friction. Therefore, the structure of the first substrate is not damaged, stretched, deformed, or wrinkled during the CCM process, and a CCM with a flat surface can be manufactured without using hot pressing processes or other additional procedures that complicate the CCM process (for example, adding processes that cause defects such as solvent removal to overcome the problems of the direct coating method). The present invention can be applied in particular to the direct coating method to manufacture single-sided or double-sided CCMs with a flat surface under minimal process constraints, achieving highly efficient industrial production. In addition, even when a thick catalyst layer is directly coated using the method of the present invention, a CCM with a flat surface can be manufactured, avoiding the problems of reduced production efficiency and yield due to multiple coatings and drying.

[0049] From the embodiments described above, at least the following forms can be understood. [1] According to one embodiment, a method for producing a catalyst coating film for a gas reaction, comprising the steps of: preparing a first substrate having a first surface; forming a first catalyst layer on the first surface of the first substrate; preparing a second substrate having a coefficient of friction in the range of 2 to 15 on the first catalyst layer; and forming the catalyst coating film with a friction coefficient of 0 kgf / cm 2 Exceeding 380 kgf / cm² 2 The process includes the step of pressurizing and laminating the first catalyst layer onto the second substrate by applying pressure to a film within the following range. [2]According to the embodiment [1], the first substrate is a polymer film. [3]According to embodiment [1] or [2], the method includes the steps of heating the first substrate to a coating temperature and forming the first catalyst layer at the coating temperature. [4] According to any of the forms [1] to [3], the coefficient of friction is a static friction coefficient in the range of 5 to 15, and the pressure on the film is 0 kgf / cm 2 Exceeding 50 kgf / cm² 2 It is within the following range. [5] According to any of the forms [1] to [3], the coefficient of friction is a static friction coefficient in the range of 10 to 15, and the pressure on the film is 0 kgf / cm 2 Exceeding 10 kgf / cm² 2 It is within the following range. [6]According to any of the embodiments [1] to [5], the second substrate comprises at least one material of silicone, rubber, silicone rubber, and polymer. [7] According to any of the embodiments [1] to [6], the lamination step is carried out in a vacuum environment. [8]According to any of the embodiments [1] to [7], the method further includes the steps of heating the first substrate to a coating temperature and forming the second catalyst layer on the first substrate having a second surface at the coating temperature. [9]According to any of the forms [1] to [8], the first catalyst layer or the second catalyst layer is applied by a roll-to-roll (R2R) coating method, a brush coating method, an ultrasonic coating method, a blade coating method, a transfer printing method, or a screen printing method.

[10] According to any of the embodiments [1] to [9], a catalyst coating film manufactured by the manufacturing method described in any one of claims 1 to 9.

[11] According to one embodiment, a method for producing a catalyst coating film for a gas reaction, comprising the steps of preparing a sandwich structure including a first substrate, a second substrate having a friction coefficient in the range of 2 to 15, and a catalyst layer sandwiched between the first substrate and the second substrate, and 0 kgf / cm 2 Exceeding 380 kgf / cm² 2 The step of pressurizing and stacking the sandwich structure at a pressure within the following range is included.

[12] According to one embodiment, a method for producing a catalyst coating film for a gas reaction, comprising the steps of: preparing a substrate having a first surface, a second surface, and a first protective film and a second protective film protecting the first surface and the second surface, respectively; removing the first protective film; coating the first surface with a first catalyst layer; covering the first catalyst layer with a protective layer and replacing the first protective film; removing the second protective film; and coating the second surface with a second catalyst layer.

[13] According to the embodiment

[12] , the substrate is a polymer film, and the protective layer has a coefficient of friction in the range of 2 to 15.

[14] According to the form

[12] or

[13] , the substrate, the first catalyst layer and the protective layer are set to 0 kgf / cm 2 Exceeding 380 kgf / cm² 2 The further step includes pressurizing and laminating at a pressure within the following range.

[15] In one embodiment, the present invention includes a first substrate, a second substrate having a coefficient of friction in the range of 2 to 15 and comprising at least one material of silicone, rubber, silicone rubber, and polymer, and a catalyst layer sandwiched between the first substrate and the second substrate.

[0050] Although the present invention has been described above using embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various modifications or improvements can be made to the above embodiments. It will be clear from the claims that such modified or improved forms may also be included in the technical scope of the present invention. [Explanation of Symbols]

[0051] 21:First board 22:Second board 23: First catalyst layer 24:Second catalyst layer S1~S5: Step

Claims

1. A method for producing a catalyst coating film for gas reactions, The steps include: preparing a first substrate having a first surface, The steps include forming a first catalyst layer on the first surface of the first substrate, The first catalyst layer is prepared with a second substrate having a friction coefficient in the range of 2 to 15, To form the catalyst coating film, 0 kgf / cm ２ It exceeds 380 kgf / cm² ２ A method characterized by comprising the step of pressurizing and laminating the first catalyst layer onto the second substrate by applying pressure to a film within the following range.

2. The first substrate is a polymer film, The aforementioned coefficient of friction is a static friction coefficient in the range of 10 to 15. The pressure on the aforementioned membrane is 0 kgf / cm². ２ Exceeding 10 kgf / cm² ２ It is within the following range: The method according to claim 1, characterized in that the second substrate comprises at least one material from silicone, rubber, silicone rubber, and polymer.

3. The steps include heating the first substrate to a coating temperature, The step includes forming the first catalyst layer at the coating temperature, The method according to claim 1, characterized in that the lamination step is performed in a vacuum environment.

4. The steps include heating the first substrate to a coating temperature, The process further includes the step of forming the second catalyst layer on the first substrate having a second surface at the aforementioned coating temperature, The method according to claim 1, characterized in that the first catalyst layer or the second catalyst layer is applied by a roll-to-roll (R2R) coating method, a brush coating method, an ultrasonic coating method, a blade coating method, a transfer printing method, or a screen printing method.

5. A catalyst coating film manufactured by the manufacturing method described in any one of claims 1 to 4.

6. A method for producing a catalyst coating film for gas reactions, The steps include: preparing a sandwich structure comprising a first substrate, a second substrate having a friction coefficient in the range of 2 to 15, and a catalyst layer sandwiched between the first and second substrates; 0 kgf / cm ２ It exceeds 380 kgf / cm² ２ A method characterized by comprising the step of pressurizing and stacking the sandwich structure at a pressure within the following range.

7. A method for producing a catalyst coating film for gas reactions, The steps include: preparing a substrate having a first surface, a second surface, and a first protective film and a second protective film that protect the first surface and the second surface, respectively; The step of removing the first protective film, The steps include coating the first surface with a first catalyst layer, The steps include covering the first catalyst layer with a protective layer and replacing the first protective film, The step of removing the second protective film, A method characterized by comprising the step of coating the second surface with a second catalyst layer.

8. The aforementioned substrate is a polymer film, The protective layer has a coefficient of friction in the range of 2 to 15. The substrate, the first catalyst layer, and the protective layer are subjected to a load of 0 kgf / cm². ２ It exceeds 380 kgf / cm² ２ The method according to the present invention, further comprising the step of pressurizing and laminating at a pressure within the following range.

9. First circuit board and A second substrate having a coefficient of friction in the range of 2 to 15, comprising at least one material of silicone, rubber, silicone rubber, and polymer, A catalyst coating film for gas reactions, characterized by comprising a catalyst layer sandwiched between the first substrate and the second substrate.

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