Membrane electrode assembly and method for manufacturing the same
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- WL GORE & ASSOC INC
- Filing Date
- 2024-05-15
- Publication Date
- 2026-06-09
AI Technical Summary
【0014】 さらに、第1の電極の第2の多孔質支持体は、強化電極層のプロトン抵抗の増加を避けるために、単位面積あたりの質量が小さい状態で提供することができる。第1の電極の第2の多孔質支持体の厚さは、第1の電極の厚さに合わせて選択することができ、例えば15μmであってよい。
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Figure 2026518668000001_ABST
Abstract
Claims
1. A film electrode assembly for an electrochemical device, wherein the film electrode assembly is - A composite electrolyte membrane comprising a reinforced electrolyte layer including at least one first porous support, wherein the at least one first porous support includes a first porous support in which a first ion exchange material is at least partially incorporated, - A first electrode comprising a reinforced electrode layer including a second porous support, wherein the second porous support incorporates at least a second ion exchange material and a first catalyst, and Equipped with, The composite electrolyte membrane is in contact with the first electrode, forming a membrane electrode assembly.
2. The membrane electrode assembly according to claim 1, wherein the first porous support of the reinforced electrolyte layer and the second porous support of the reinforced electrode layer are the same porous support.
3. The membrane electrode assembly according to claim 1, wherein the first porous support of the reinforced electrolyte layer and the second porous support of the reinforced electrode layer are different porous supports.
4. The membrane electrode assembly according to any one of claims 1 to 3, wherein the first porous support has a first bubble point, the second porous support has a second bubble point, and the second bubble point of the second porous support is smaller than the first bubble point of the first porous support.
5. The membrane electrode assembly according to claim 4, wherein the first porous support is in contact with the second porous support.
6. The membrane electrode assembly according to claim 4 or 5, wherein the first porous support and the second porous support are integrally formed.
7. The membrane electrode assembly according to any one of claims 4 to 6, further comprising a second electrode containing a second catalyst and a third ion exchange material, wherein the second electrode is in contact with the composite electrolyte membrane, and the composite electrolyte membrane is located between the first electrode and the second electrode.
8. The membrane electrode assembly according to claim 4, wherein the membrane electrode assembly includes a layer of the first ion exchange material between the first porous support and the second porous support, and the layer is a first unreinforced electrolyte layer.
9. The membrane electrode assembly according to claim 8, wherein the first unreinforced electrolyte layer further comprises a recombination catalyst.
10. The membrane electrode assembly according to claim 7, wherein the membrane electrode assembly includes a layer of the first ion exchange material between the reinforced electrolyte layer and the second electrode, and the layer is a second non-reinforced electrolyte layer.
11. The membrane electrode assembly according to claim 10, wherein the second unreinforced electrolyte layer further comprises a recombination catalyst.
12. The membrane electrode assembly according to any one of claims 4 to 11, wherein the first catalyst and the second ion exchange material are completely incorporated into the second porous support, thereby providing the reinforced electrode layer.
13. The membrane electrode assembly according to any one of claims 4 to 11, wherein the first catalyst and the second ion exchange material are partially incorporated into the second porous support, thereby providing the reinforced electrode layer.
14. The membrane electrode assembly according to claim 10 or 11, wherein the first ion exchange material is further partially incorporated into the second porous support.
15. The membrane electrode assembly according to claim 14, wherein the recombination catalyst is further partially incorporated into the second porous support.
16. The membrane electrode assembly according to claim 14 or 15, wherein the first ion exchange material further partially incorporated into the second porous support is in contact with the first ion exchange material in the layer of the first ion exchange material between the first porous support and the second porous support, or the first ion exchange material further partially incorporated into the second porous support is in contact with the first ion exchange material of the first porous support in which the first ion exchange material is at least partially incorporated.
17. The membrane electrode assembly according to any one of claims 4 to 16, wherein the reinforced electrode layer of the first electrode includes a first surface and a second surface on the opposite side, and the first electrode further includes a non-reinforced electrode layer containing the first catalyst and the second ion exchange material in contact with the second surface of the reinforced electrode layer.
18. The membrane electrode assembly according to any one of claims 4 to 17, wherein the first bubble point of the first porous support is 100 kPa or more, 200 kPa or more, 300 kPa or more, 400 kPa or more, or 500 kPa or more.
19. The membrane electrode assembly according to any one of claims 4 to 18, wherein the second bubble point of the second porous support is less than 100 kPa, 50 kPa or less, 25 kPa or less, or 5 kPa or less.
20. The membrane electrode assembly according to any one of claims 4 to 17, wherein the second porous support has a second bubble point of less than 50 kPa, and the first porous support has a first bubble point of more than 400 kPa.
21. The membrane electrode assembly according to any one of claims 4 to 20, wherein the difference between the bubble point of the first porous support and the bubble point of the second porous support is at least 50 kPa, at least 200 kPa, at least 300 kPa, or at least 350 kPa.
22. The mass per unit area of the first porous support is 10 g / m². ２ Less than 5 g / m ２ Less than 2.5 g / m² ２ A membrane electrode assembly according to any one of claims 4 to 21, wherein the value is less than [amount missing].
23. The mass per unit area of the second porous support is 3 g / m². ２ Less than 1.5 g / m ２ A membrane electrode assembly according to any one of claims 4 to 21, wherein the value is less than [amount missing].
24. The membrane electrode assembly according to any one of claims 4 to 23, wherein the ion exchange material comprises at least one ionomer.
25. The membrane electrode assembly according to claim 24, wherein the at least one ionomer has a density of about 1.9 g / cc or more at a relative humidity of 0%.
26. The membrane electrode assembly according to any one of claims 4 to 25, wherein the first ion exchange material and the second ion exchange material are the same or different.
27. The membrane electrode assembly according to any one of claims 4 to 26, wherein the first porous support and the second porous support independently comprise a fluorinated polymer or a hydrocarbon polymer.
28. The membrane electrode assembly according to claim 27, wherein the fluorinated polymer is polytetrafluoroethylene (PTFE), poly(ethylene-co-tetrafluoroethylene) (EPTFE), stretched polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), stretched polyvinylidene fluoride (ePVDF), stretched poly(ethylene-co-tetrafluoroethylene) (eEPTFE), or a mixture thereof.
29. The membrane electrode assembly according to claim 27, wherein the hydrocarbon polymer comprises polyethylene, polypropylene, polycarbonate, polystyrene, or a mixture thereof.
30. The film electrode assembly according to claim 7, wherein the first electrode is a cathode and the second electrode is an anode, or the first electrode is an anode and the second electrode is a cathode.
31. A fuel cell comprising a membrane electrode assembly according to any one of claims 1 to 30.
32. An electrolytic cell comprising a membrane electrode assembly according to any one of claims 1 to 30.
33. A composite electrolyte membrane, wherein the composite electrolyte membrane is a) At least one first porous support comprising a first porous support, b) A second porous support, c) A first ion exchange material at least partially embedded within the first porous support, wherein a reinforced electrolyte layer is provided and at least a portion of the first porous support is closed off. Includes, d) The second porous support includes a non-incorporation region that is substantially free of the first ion exchange material, Composite electrolyte membrane.
34. The composite electrolyte membrane according to claim 33, wherein the first porous support and the second porous support are the same porous support.
35. The composite electrolyte membrane according to claim 33, wherein the first porous support and the second porous support are different porous supports.
36. The composite electrolyte membrane according to claim 33, wherein the composite electrolyte membrane includes a first surface and a second surface on the opposite side, and the first surface is formed by the non-incorporation region of the second porous support.
37. The composite electrolyte membrane according to any one of claims 33 to 36, wherein the first porous support has a first bubble point, the second porous support has a second bubble point, and the second bubble point of the second porous support is smaller than the first bubble point of the first porous support.
38. The composite electrolyte membrane according to claim 37, wherein the first bubble point of the first porous support is 100 kPa or more, 200 kPa or more, 300 kPa or more, 400 kPa or more, or 500 kPa or more.
39. The composite electrolyte membrane according to claim 37 or 38, wherein the second bubble point of the second porous support is less than 100 kPa, 50 kPa or less, 25 kPa or less, or 5 kPa or less.
40. The composite electrolyte membrane according to any one of claims 37 to 39, wherein the second porous support has a second bubble point of less than 50 kPa, and the first porous support has a first bubble point of more than 400 kPa.
41. The composite electrolyte membrane according to any one of claims 37 to 40, wherein the difference between the bubble point of the first porous support and the bubble point of the second porous support is at least 50 kPa, at least 200 kPa, at least 300 kPa, or at least 350 kPa.
42. The mass per unit area of the first porous support is 10 g / m². ２ Less than 5 g / m ２ Less than 2.5 g / m² ２ A composite electrolyte membrane according to any one of claims 33 to 41, wherein the value is less than [value missing].
43. The mass per unit area of the second porous support is less than 3 g / m ２ or less than 1.5 g / m ２ The composite electrolyte membrane according to any one of claims 33 to 42, which is less.
44. The composite electrolyte membrane according to claim 33, wherein the first porous support and the second porous support are in direct contact or not in direct contact.
45. The composite electrolyte membrane according to claim 33, wherein the first porous support and the second porous support are integrally formed.
46. The composite electrolyte membrane according to claim 33, wherein at least one layer of the first ion exchange material and optionally a recombination catalyst is provided between the first porous support and the second porous support.
47. The composite electrolyte membrane according to claim 33, wherein the first ion exchange material and optionally a recombination catalyst are partially incorporated into the second porous support.
48. The composite electrolyte membrane according to claim 47, wherein the first ion exchange material further partially incorporated into the second porous support is in contact with the first ion exchange material in the layer of the first ion exchange material between the first porous support and the second porous support, or the first ion exchange material further partially incorporated into the second porous support is in contact with the first ion exchange material of the first porous support in which the first ion exchange material is at least partially incorporated.
49. The composite electrolyte membrane according to claim 33, wherein the reinforced electrolyte layer has a first surface and a second surface on the opposite side, and the first ion exchange material forms a layer on either or both of the first surface and the second surface.
50. The composite electrolyte membrane according to any one of claims 33 to 49, wherein the first ion exchange material is completely incorporated into the first porous support.
51. The composite electrolyte membrane according to claim 47 or 48, wherein less than 20%, less than 10%, or less than 5% of the second porous support is occluded with the first ion exchange material.
52. The composite electrolyte membrane according to claim 33, wherein the second porous support substantially does not include a occluded portion or a layer of the first ion exchange material.
53. The composite electrolyte membrane according to any one of claims 33 to 52, wherein the first porous support and the second porous support independently comprise a fluorinated polymer or a hydrocarbon polymer.
54. The composite electrolyte membrane according to claim 53, wherein the fluorinated polymer is polytetrafluoroethylene (PTFE), poly(ethylene-co-tetrafluoroethylene) (EPTFE), stretched polytetrafluoroethylene (ePTFE), polyvinylidene fluoride (PVDF), stretched polyvinylidene fluoride (ePVDF), stretched poly(ethylene-co-tetrafluoroethylene) (eEPTFE), or a mixture thereof.
55. The composite electrolyte membrane according to claim 53, wherein the hydrocarbon polymer comprises polyethylene, polypropylene, polycarbonate, polystyrene, or a mixture thereof.
56. The composite electrolyte membrane according to any one of claims 33 to 55, wherein the ion exchange material comprises at least one ionomer, optionally the at least one ionomer comprising a proton-conducting polymer, and further optionally the proton-conducting polymer comprising a hydrocarbon ionomer, a perfluoroionomer, or a perfluorosulfonic acid.
57. A method for manufacturing a membrane electrode assembly, - A step of providing a composite electrolyte membrane having a first surface and a second surface on the opposite side, wherein the composite electrolyte membrane comprises a first porous support and a second porous support, the first porous support having at least partially incorporated a first ion exchange material so as to provide a reinforced electrolyte membrane; the second porous support includes a non-incorporation region, the non-incorporation region substantially free of the first ion exchange material and forming the first surface of the composite electrolyte membrane, - A step of providing a first electrode composition comprising a first catalyst, a second ion exchange material, and a liquid carrier, - The step of applying the first electrode composition to the first surface of the composite electrolyte membrane and the non-incorporation region of the second porous support, thereby partially incorporating the first catalyst and the second ion exchange material into the second porous support, and thereby providing a second porous support into which the first electrode composition has been incorporated. - A step of heating the second porous support into which the first electrode composition is incorporated to remove the liquid carrier from the first electrode composition, thereby providing a first electrode having a reinforced electrode layer. A method that includes at least the following.
58. The method according to claim 57, wherein the first ion exchange material and optionally the recombination catalyst are partially incorporated into the second porous support, thereby providing a region of the second porous support into which the first ion exchange material and optionally the recombination catalyst are incorporated.
59. The method according to claim 57 or 58, further comprising the step of applying the first electrode composition to provide a layer of the first electrode composition on a second porous support into which the first electrode composition is incorporated, thereby providing a non-reinforced electrode layer in contact with the reinforced electrode layer by the step of heating the second porous support into which the first electrode composition is incorporated.
59. The composite electrolyte membrane has a second surface opposite to the first surface, and the method is as follows: - A step of providing a second electrode composition comprising a second catalyst, a third ion exchange material, and a liquid carrier, - The step of applying the second electrode composition to the second surface of the composite electrolyte membrane to provide a layer of the second electrode composition, - The step of heating the layer of the second electrode composition to remove the liquid carrier from the layer of the second electrode composition, thereby providing the second electrode. The method according to claim 57 or 58, further comprising:
60. A method for manufacturing a composite electrolyte membrane, - A step of providing a peelable backing layer, - A step of applying a first electrolyte composition comprising a first ion exchange material and a liquid carrier to the peelable backing layer as a layer of controlled thickness using a single-pass or multi-pass coating technique, - A step of laminating a first porous support onto at least a portion of the layer of the first electrolyte composition, thereby incorporating the first electrolyte composition into the first porous support, and thereby providing a first porous support into which the first electrolyte composition is incorporated. - A step of heating the first porous support into which the first electrolyte composition has been incorporated to remove the liquid support, thereby providing a reinforced electrolyte layer, - A step of laminating a second electrolyte composition, comprising a first ion exchange material and a liquid carrier, onto a reinforced electrolyte layer as a layer of controlled thickness using a single-pass or multi-pass coating technique, - The step of applying the second porous support to at least a portion of the layer of the second electrolyte composition, - The step of heating the second electrolyte composition to remove the liquid support and A method that includes at least the following.
61. The method according to claim 60, wherein the second electrolyte composition further comprises a recombination catalyst.