Electrode catalyst containing porous silicon nitrooxy carbide composite material, electrode for fuel cell, fuel cell, and method for manufacturing electrode catalyst

Abstract

The purpose of the present invention is to provide an electrode catalyst containing a porous silicon nitrooxy carbide composite material having both a high BET specific surface area and high conductivity, an electrode for a fuel cell, and a fuel cell, and a method for manufacturing the electrode catalyst containing a porous silicon nitrooxy carbide composite material capable of controlling the pore diameter by using an organic alkoxysilane of a type widely distributed as an industrial raw material. The electrode catalyst according to the present invention comprises: a porous silicon nitrooxy carbide composite material that contains silicon nitrooxy carbide (SiCNO) and a carbon material; and particles that are supported on the porous silicon nitrooxy carbide composite material and contain a noble metal. The porous silicon nitrooxy carbide composite material has a BET specific surface area of 100 m2 / g-400 m2 / g, and a conductivity of 1.0-25 S / cm.

Description

Electrode catalyst containing porous silicon nitroxycarbide composite material, fuel cell electrode, fuel cell, and method for producing said electrode catalyst

[0001] The present invention relates to an electrode catalyst containing a porous silicon nitroxycarbide composite material, a fuel cell electrode, a fuel cell, and a method for producing the electrode catalyst. This application claims priority from Japanese Patent Application No. 2024-077520, filed May 10, 2024, the contents of which are incorporated herein by reference.

[0002] A fuel cell is a device that generates electricity and heat through a chemical reaction that converts hydrogen and oxygen into water. Examples of fuel cells include phosphoric acid fuel cells (PAFCs), molten carbonate fuel cells (MCFCs), solid oxide fuel cells (SOFCs), and polymer electrolyte fuel cells (PEFCs).

[0003] Among these, a polymer electrolyte fuel cell (PEFC) generally has a structure in which a catalyst layer constituting an anode (fuel electrode) is provided on one side of a solid polymer electrolyte membrane and a catalyst layer constituting a cathode (air electrode) is provided on the other side, and a gas diffusion layer is attached to the outside of each catalyst layer. The catalyst layer is composed of a catalyst-supported carrier in which particulate catalyst containing, for example, a precious metal is highly dispersed and supported on the surface of nano-level support particles.

[0004] Currently, carbon-based materials with high specific surface area and high electrical conductivity are used as catalyst supports. However, deterioration of catalytic performance due to corrosion of the carbon support has become a major problem in the cathode and anode. Therefore, there is an urgent need to develop a material with high specific surface area, high electrical conductivity, and excellent durability to replace carbon.

[0005] For example, Patent Document 1 discloses an electrode catalyst including (A) Group 13-doped SiC (SiC doped with a Group 13 (Group 3B) element), (B) conductive carbon particles, and (C) a noble metal supported on the surface of the (A) Group 13-doped SiC. The Group 13 element doped into the SiC is, for example, aluminum (Al), and the doping amount of the Group 13 element in the (A) Group 13-doped SiC is 1 to 5 mol %, and the ratio of the (A) Group 13-doped SiC to the (B) conductive carbon particles [(A):(B)] is 1:9 to 5:5 by weight.

[0006] Patent Document 2 discloses noble metal-supported silicon carbide particles having a silicon oxide layer on the surface of silicon carbide particles having an average primary particle diameter of 0.005 μm to 5 μm, with noble metal particles supported thereon. The specific surface area of ​​the silicon carbide particles is 1.0 m. ２ / g~400m ２ / g.

[0007] JP 2010-149008 A JP 2011-093756 A

[0008] Fuel cell electrodes that achieve high efficiency and high output require supports that combine a large specific surface area with high electrical conductivity. Patent Document 1 describes an electrode catalyst that contains silicon carbide particles carrying a noble metal and conductive carbon particles to provide electrical conductivity, but does not mention durability, leaving room for improvement. In particular, there is a need for an electrode catalyst that can demonstrate high durability even during start-stop cycles, which are the most susceptible to deterioration under the power generation conditions of a fuel cell.

[0009] The above-mentioned Patent Document 2 describes noble metal-supported silicon carbide particles having a silicon oxide layer on the surface of silicon carbide supporting noble metal particles, but does not mention that the silicon carbide particles are porous, nor does it mention electrical conductivity.

[0010] The present invention has been made in view of the above circumstances, and aims to provide an electrode catalyst, a fuel cell electrode, and a fuel cell containing a porous silicon nitroxycarbide composite material that has both a high BET specific surface area and high electrical conductivity, and to provide a method for producing an electrode catalyst containing a porous silicon nitroxycarbide composite material whose pore size can be controlled.

[0011] The inventors discovered that by preparing a precursor gel by adding a carbon material or organic polymer as a carbon source during the sol-gel reaction of an organic alkoxysilane aqueous solution in the presence of a surfactant, while taking care not to interfere with the formation of the porous gel, and then firing the precursor gel under a nitrogen atmosphere, a porous silicon nitroxycarbide composite material was produced in which a mesoscopic pore structure (mesopores) developed into a macroscopic pore structure (macropores) and the carbon material was arranged at the nanometer level within a porous three-dimensional framework. Furthermore, by gradually progressing the polysilsesquioxane condensation polymerization reaction while adjusting the pH to form a precursor gel with a porous structure, the carbon material could be densely dispersed within the porous three-dimensional framework, resulting in a porous silicon nitroxycarbide composite material with higher conductivity. They further discovered that mixing the resulting porous silicon nitroxycarbide composite material with a dispersion containing a precious metal-containing colloidal dispersion produced an electrocatalyst containing precious metal particles.

[0012] That is, the present invention provides the following: [1] A porous silicon nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material, and particles containing a noble metal supported on the porous silicon nitroxycarbide composite material, wherein the BET specific surface area of ​​the porous silicon nitroxycarbide composite material is 100 m ２ / g or more 400m ２ / g or less, and the conductivity of the porous silicon nitroxycarbide composite material is 1.0 S / cm or more and 25 S / cm or less. [2] The electrode catalyst according to [1], wherein the amount of the particles containing the noble metal is 10 mass% or more and 60 mass% or less, when the total mass of the electrode catalyst is taken as 100 mass%. [3] The electrode catalyst according to [1] or [2], wherein the content of the carbon material is 5 mass% or more and 50 mass% or less. [4] The electrode catalyst according to any of [1] to [3], wherein the carbon material is composed of one or more selected from the group consisting of carbon black, carbon nanofiber, carbon nanotube, and low-crystalline nanocarbon. [5] The electrode catalyst according to any of [1] to [4], wherein the particles containing the noble metal are composed of one or more selected from the group consisting of platinum (Pt), platinum-cobalt alloy (PtCo), and platinum-nickel alloy (PtNi). [6] The electrode catalyst according to any of [1] to [4], wherein the total pore volume of the porous silicon nitroxycarbide composite material is 1.3 cm or more. ３ / g or more 2.5cm ３ / g or less. [7] The electrode catalyst according to any of [1] to [6], wherein the pore size of the porous silicon nitroxycarbide composite material is 10 nm or more and 500 nm or less. [8] The electrode catalyst according to any of [1] to [7], wherein the mass ratio of carbon (C) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([C] / [Si]) is 3.0 or more and 8.0 or less. [9] The electrode catalyst according to any of [1] to [8], wherein the mass ratio of oxygen (O) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([O] / [Si]) is 0.2 or more and 1.5 or less.

[10] The electrode catalyst according to any one of [1] to [9], wherein the mass ratio of nitrogen (N) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([N] / [Si]) is 0.05 or more and 2.0 or less.

[11] A fuel cell electrode having a layer containing the electrode catalyst according to any one of [1] to

[10] .

[12] A fuel cell comprising the fuel cell electrode according to

[11] .

[13] A method for producing an electrocatalyst, comprising: (A) adding an organic alkoxysilane to an acidic aqueous solution containing a surfactant and a pH adjuster, and further adding a carbon material or an organic polymer to form a gel containing the carbon material or the organic polymer through a sol-gel reaction of the organic alkoxysilane; (B) washing the gel with alcohol; (C) drying the washed gel to form a porous silicon nitroxycarbide precursor; (D) calcining the porous silicon nitroxycarbide precursor in a nitrogen-containing atmosphere to obtain a porous silicon nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material; and (E) mixing the porous silicon nitroxycarbide composite material with a dispersion containing a noble metal colloid and hydrogen peroxide solution to obtain an electrocatalyst containing noble metal particles.

[14] The method for producing an electrocatalyst according to

[13] , wherein in step (D), the porous silicon nitroxycarbide precursor is calcined at 1100°C or higher but lower than 1450°C.

[15] The method for producing an electrode catalyst according to either

[13] or

[14] , wherein the organic alkoxysilane is represented by the following formula (1) or formula (2): R. １ -SiR ２ ｘ (OR ３ ) ３－ｘ ...(1) (in the formula R １ is any group selected from a methyl group, an ethyl group, a vinyl group, and a phenyl group, and R ２ is a methyl group, R ３ represents a methyl group or an ethyl group. In the formula, the integer x is 0 or 1. ４ -(SiR ５ ｙ (OR ６ ) ３－ｙ ) ２ ...(2) (in the formula R ４ contains any group selected from a methylene group, an ethylene group, a hexylene group, a vinylene group, a phenylene group, and a biphenylene group, and R ５ is a methyl group, R ６ represents a methyl group or an ethyl group. In the formula, the integer y is 0 or 1.)

[16] The method for producing an electrode catalyst according to any one of

[13] to

[15] , wherein the carbon material is one or more types selected from carbon black, carbon nanofibers, carbon nanotubes, and low-crystalline nanocarbons.

[17] The method for producing an electrode catalyst according to any one of

[13] to

[16] , wherein the colloid containing a noble metal is one or more types selected from the group consisting of platinum (Pt) colloid, platinum-cobalt alloy (PtCo) colloid, and platinum-nickel alloy (PtNi) colloid.

[18] The method for producing an electrode catalyst according to any one of

[13] to

[17] , wherein the mass ratio of the carbon material or the organic polymer to the organic alkoxysilane is 2.5 to 50:97.5 to 50.

[19] The method for producing an electrode catalyst according to any one of

[13] to

[18] , wherein the organic polymer is composed of one or more selected from a phenolic resin, polystyrene, and polydivinylbenzene.

[0013] The present invention provides an electrode catalyst containing a porous silicon nitroxycarbide composite material that has both a high BET specific surface area and high electrical conductivity, an electrode for a fuel cell, and a fuel cell. It also provides a method for producing an electrode catalyst containing a porous silicon nitroxycarbide composite material whose pore size can be controlled using an organic alkoxysilane of the type widely available as an industrial raw material.

[0014] 1 is a flowchart illustrating an example of a method for manufacturing an electrode catalyst according to an embodiment of the present invention. It is a scanning electron microscope image of a porous silicon nitroxycarbide composite material (Synthesis Example 2, SC2). It is an X-ray diffraction pattern of a porous silicon nitroxycarbide composite material (Synthesis Example 2, SC2). It is a Si-NMR measurement result of a porous silicon nitroxycarbide composite material (Synthesis Example 2, SC2). It is a flowchart showing the steps of a method for manufacturing a porous silicon nitroxycarbide composite material according to an embodiment of the present invention. It is a transmission electron microscope image of electrode catalyst B. It is a diagram showing the results of cyclic voltammetry (CV) measurement of electrode catalyst B. It is a diagram showing the change in electrochemically active surface area (ECSA) of electrode catalyst B with respect to the CV measurement cycle.

[0015] A porous silicon nitroxycarbide composite material, a fuel cell electrode, and a method for producing the porous silicon nitroxycarbide composite material according to one embodiment of the present invention will now be described with reference to the drawings. The following embodiments are specifically described to facilitate a better understanding of the spirit of the invention, and unless otherwise specified, are not intended to limit the scope of the present invention. Furthermore, the drawings used in the following description may show key portions enlarged for the sake of clarity, and the dimensional proportions of the components may not necessarily be the same as those in the actual drawings.

[0016] <Configuration of Electrode Catalyst> The electrode catalyst according to this embodiment comprises a porous silicon nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material, and particles containing a precious metal supported on the porous silicon nitroxycarbide composite material.

[0017] The form of the electrode catalyst is not particularly limited, but may be, for example, powder, particulate, fibrous, or acicular, of which powder or particulate is preferred. When the electrode catalyst is powder or particulate, the particle size of the electrode catalyst is not particularly limited. The particle size D at 50% of the cumulative particle size in the volume-based cumulative particle size distribution is ５０ For example, the thickness is preferably 0.1 μm or more and 50 μm or less, more preferably 0.1 μm or more and 10 μm or less, and even more preferably 0.1 μm or more and 2 μm or less.

[0018] Electrode catalyst particle diameter D ５０ means a value measured in accordance with JIS Z8825-1:2013, and is, for example, a particle diameter D measured using a laser diffraction particle size distribution analyzer (Shimadzu Corporation, SALD-7000). ５０ means:

[0019] The electrode catalyst of this embodiment has a BET specific surface area of ​​100 m ２ / g or more, and 150m ２ / g or more, and ２ / g or more. The BET specific surface area is preferably 400 m ２ / g or less. ２ When the BET specific surface area is 400 m / g or more, the amount of catalyst particles carried on the surface of the carrier is sufficiently ensured, and when the electrode catalyst is used in a fuel cell electrode, desired characteristics such as output and efficiency can be obtained. ２ / g or less, the proportion of mesopores suitable for supporting the catalyst increases, and the catalyst particle utilization rate can be further improved.

[0020] The total pore volume of the electrode catalyst is 1.3 cm ３ / g or more, and ３ / g or more, and more preferably 2.0 cm ３ It is particularly preferred that the total pore volume of the electrode catalyst is 1.3 cm3 / g or more. ３ When the SiO 2 content is 1 / g or more, the reaction gas and electrolyte can easily flow through the catalyst layer, and the catalytic efficiency can be improved.

[0021] The pore diameter of the electrode catalyst is preferably 10 nm or more and 500 nm or less, more preferably 20 nm or more and 400 nm or less, and particularly preferably 50 nm or more and 300 nm or less. When the pore diameter of the electrode catalyst is 10 nm or more and 1000 nm or less, the flow of the reactant gas and electrolyte within the catalyst layer is facilitated, thereby improving the catalytic efficiency. In particular, when the pore diameter of the porous silicon nitroxycarbide composite material is 10 nm or more, the supply of the reactant gas and electrolyte to the supported catalyst particles is stabilized, thereby preventing a decrease in the catalyst particle utilization rate.

[0022] The BET specific surface area, total pore volume, and pore diameter of the electrode catalyst can be calculated as measured values ​​by a gas adsorption method, for example, by using a constant volume method to adsorb a noncorrosive gas such as nitrogen or argon while changing the relative pressure in the adsorption isotherm, and the values ​​are calculated from the adsorption amount and condensation of the noncorrosive gas.

[0023] <Configuration of Porous Silicon Nitroxycarbide Composite Material> The porous silicon nitroxycarbide composite material according to this embodiment is a porous nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material. The porous silicon nitroxycarbide composite material has a BET specific surface area of ​​100 m ２ / g or more 400m ２ / g or less, and the electrical conductivity is in the range of 1.0 S / cm or more and 25 S / cm or less.

[0024] The form of the porous silicon nitroxycarbide composite material is not particularly limited, but may be, for example, powder, particulate, fibrous, or needle-like, of which powder or particulate is preferred. When the porous silicon nitroxycarbide composite material is in powder or particulate form, the particle size of the porous silicon nitroxycarbide composite material is not particularly limited, but it is preferably a particle size D of 50% of the cumulative particle size in the volume-based cumulative particle size distribution. ５０ For example, the thickness is preferably 0.05 μm or more and 50 μm or less, more preferably 0.1 μm or more and 10 μm or less, and even more preferably 0.1 μm or more and 2 μm or less.

[0025] Particle diameter D of porous silicon nitroxycarbide composite material ５０ means a value measured in accordance with JIS Z8825-1:2013, and is, for example, a particle diameter D measured using a laser diffraction particle size distribution analyzer (Shimadzu Corporation, SALD-7000). ５０ means:

[0026] The porous silicon nitroxycarbide composite material of this embodiment has a BET specific surface area of ​​100 m ２ / g or more, and 150m ２ / g or more, and ２ / g or more. ２ / g or more, the amount of catalyst particles supported on the support surface is sufficiently ensured, and when the porous silicon nitroxycarbide composite material is used in a fuel cell electrode, desired characteristics such as output and efficiency can be obtained. ２ / g or less, the proportion of mesopores suitable for supporting the catalyst increases, and the catalyst particle utilization rate can be further improved.

[0027] The total pore volume of the porous silicon nitroxycarbide composite is 1.3 cm ３ / g or more 2.5cm ３ / g or less, and ３ / g or more 2.5cm ３ / g or less, and more preferably 2.0 cm ３ / g or more 2.5cm ３ It is particularly preferred that the total pore volume of the porous silicon nitroxycarbide composite material is 1.3 cm3 / g or less. ３ When the SiO 2 content is 1 / g or more, the reaction gas and electrolyte can easily flow through the catalyst layer, and the catalytic efficiency can be improved.

[0028] The pore diameter of the porous silicon nitroxycarbide composite material is preferably 10 nm or more and 500 nm or less, more preferably 20 nm or more and 400 nm or less, and particularly preferably 50 nm or more and 300 nm or less. When the pore diameter of the porous silicon nitroxycarbide composite material is 10 nm or more and 500 nm or less, the flow of the reaction gas and electrolyte within the catalyst layer is facilitated, thereby improving the catalytic efficiency. In particular, when the pore diameter of the porous silicon nitroxycarbide composite material is 10 nm or more, the supply of the reaction gas and electrolyte to the supported catalyst particles is stabilized, thereby preventing a decrease in the catalyst particle utilization rate.

[0029] The BET specific surface area, total pore volume, and pore diameter of the porous silicon nitroxycarbide composite material can be calculated as measured values ​​by gas adsorption, for example, by using a constant volume method to adsorb a noncorrosive gas such as nitrogen or argon while changing the relative pressure in the adsorption isotherm, and calculating the values ​​from the adsorption amount and condensation of the noncorrosive gas.

[0030] In the porous silicon nitroxycarbide that constitutes the porous silicon nitroxycarbide composite material, a plurality of micropores are provided independently by a three-dimensional framework structure, or some or all of the micropores are provided in a state where they are interconnected.

[0031] This porous silicon nitroxycarbide composite material contains carbon that constitutes the three-dimensional skeletal structure of porous silicon nitroxycarbide (SiCNO) as a carrier, and a carbon material other than the carbon that constitutes the three-dimensional skeletal structure, which is supported on the porous silicon nitroxycarbide.

[0032] In this specification, porous silicon nitroxycarbide refers to a material that is composed of spaces with a three-dimensional network structure in which silicon nitroxycarbide is linked together.

[0033] [Carbon material] The carbon material supported on the three-dimensional skeleton structure of porous silicon nitroxycarbide is not particularly limited, and may be composed of one or more selected from, for example, carbon black, carbon nanofiber, carbon nanotube, and low-crystalline nanocarbon. Among these, from the viewpoint of realizing high conductivity and manufacturability, the carbon material is preferably carbon black.

[0034] When the carbon material is carbon black, the average diameter of the primary particles of the carbon material is preferably 10 nm or more and 200 nm or less, more preferably 20 nm or more and 100 nm or less, and even more preferably 30 nm or more and 50 nm or less. When the average diameter of the primary particles of the carbon material is 10 nm or more and 200 nm or less, good electrical conductivity can be achieved.

[0035] When the carbon material is composed of carbon nanofibers or carbon nanotubes, the average diameter of the carbon material is preferably 10 nm or more and 200 nm or less, and the length of the carbon material is preferably 1 μm or more and 20 μm or less.

[0036] The morphology and size of the carbon material retained in the porous silicon nitroxycarbide composite can be measured, for example, by observation using a transmission electron microscope or a scanning electron microscope. The average diameter of the primary particles can be determined, for example, from microscope images using image analysis particle size distribution measurement software.

[0037] The content of the carbon material relative to the porous silicon nitroxycarbide is preferably 5% by mass to 50% by mass, more preferably 8% by mass to 45% by mass, and even more preferably 10% by mass to 40% by mass. When the content of the carbon material in the porous silicon nitroxycarbide composite material is 5% by mass to 50% by mass, high electrical conductivity is achieved while suppressing corrosion of the carbon, thereby improving the durability of the catalytic cycle.

[0038] The mass ratio of carbon (C) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([C] / [Si]) is preferably 3.0 to 8.0, more preferably 3.5 to 7.5, and even more preferably 4.0 to 7.0. When the mass ratio of carbon (C) to silicon (Si) ([C] / [Si]) is 3.0 to 8.0, high conductivity is achieved in the porous silicon nitroxycarbide composite material, while corrosion of the carbon and the like are suppressed, improving the durability of the catalytic cycle.

[0039] In the above mass ratios, carbon (C) refers to the sum of the carbon constituting the three-dimensional framework of the porous silicon nitroxycarbide and the carbon in the carbon material supported on the porous silicon nitroxycarbide. The carbon (C) content in the porous silicon nitroxycarbide composite material refers to a value measured, for example, by elemental analysis to determine the ratio of contained elements or by SEM-EDS (Energy Dispersive X-ray Spectroscopy) analysis. The silicon (Si) content in the porous silicon nitroxycarbide composite material refers to a value measured, for example, by elemental analysis to determine the ratio of contained elements or by SEM-EDS (Energy Dispersive X-ray Spectroscopy) analysis.

[0040] The mass ratio of oxygen (O) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([O] / [Si]) is preferably 0.2 or more and 1.5 or less, more preferably 0.3 or more and 1.4 or less, and even more preferably 0.4 or more and 1.3 or less.

[0041] The oxygen (O) content in the porous silicon nitroxycarbide composite material refers to a value measured by, for example, determining the ratio of contained elements through elemental analysis or by SEM-EDS (Energy Dispersive X-ray Spectroscopy) analysis.

[0042] The mass ratio of nitrogen (N) to silicon (Si) ([N] / [Si]) contained in the porous silicon nitroxycarbide composite material is preferably in the range of 0.05 to 2.0, more preferably in the range of 0.1 to 1.8, and even more preferably in the range of 0.5 to 1.5.

[0043] The nitrogen (N) content in the porous silicon nitroxycarbide composite material refers to a value measured, for example, by determining the ratio of contained elements through elemental analysis or by SEM-EDS (Energy Dispersive X-ray Spectroscopy) analysis. [Silicon nitroxycarbide]

[0044] The average diameter of the primary particles of silicon nitroxycarbide in the porous silicon nitroxycarbide composite material is preferably 20 nm to 200 nm, more preferably 30 nm to 150 nm, and even more preferably 40 nm to 100 nm. When the average diameter of the primary particles of silicon nitroxycarbide is 20 nm to 200 nm, good voids can be obtained when the material is used as an electrode.

[0045] The particle size of silicon nitroxycarbide in the porous silicon nitroxycarbide composite material can be measured, for example, by observation using a transmission electron microscope or a scanning electron microscope, and the average diameter of the primary particles can be determined, for example, from microscope images using image analysis particle size distribution measurement software.

[0046] [Characteristics of the Porous Silicon Nitroxycarbide Composite Material] The porous silicon nitroxycarbide composite material of this embodiment has a conductivity of 1.0 S / cm to 25 S / cm, preferably 2.0 S / cm to 25 S / cm, more preferably 3.0 S / cm to 25 S / cm, and even more preferably 5.0 S / cm to 25 S / cm. The higher the conductivity of the porous silicon nitroxycarbide, the better the fuel cell porous silicon nitroxycarbide composite material can be provided. However, if the amount of carbon material that contributes to improving conductivity is too high, oxidation corrosion of the carbon component may progress in the catalytic cycle, resulting in reduced durability. Furthermore, in one aspect of this embodiment, the porous silicon nitroxycarbide composite material does not have a characteristic peak as determined by X-ray diffraction (XRD) analysis, and is an amorphous material.

[0047] <Method for Producing Porous Silicon Nitroxycarbide Composite Material> Figure 5 is a flowchart showing the steps of a method for producing a porous silicon nitroxycarbide composite material according to one embodiment of the present invention. The method for producing a porous silicon nitroxycarbide composite material according to one embodiment of the present invention includes a gel formation step (step (A)), a washing step (step (B)), a porous silicon nitroxycarbide precursor formation step (step (C)), and a calcination step (step (D)).

[0048] It should be noted that other steps may be added before or after each step, provided that the porous silicon nitroxycarbide composite material according to this embodiment is obtained. The manufacturing method described below makes it possible to obtain a porous silicon nitroxycarbide composite material having the desired mass ratios ([C] / [Si]), ([O] / [Si]), and ([N] / [Si]) by a single firing.

[0049] [Step (A)] In step (A), for example, an organic alkoxysilane is added to an acidic aqueous solution containing a surfactant and a pH adjuster, and a carbon material or an organic polymer is further added to form a gel containing the carbon material or the organic polymer through a sol-gel reaction of the organic alkoxysilane. For example, a hydrolyzable organic alkoxysilane is hydrolyzed to produce a hydrolyzate, and the pH of the reaction system is further increased to carry out a polycondensation reaction of the organic alkoxysilane, thereby obtaining a polysilsesquioxane.

[0050] The pH suitable for the polycondensation reaction varies depending on the isoelectric point of the organic alkoxysilane used, but if the pH is too high, the reaction efficiency decreases and gel formation may become difficult. This sol-gel reaction is preferably carried out at a temperature of 25°C or higher and 80°C or lower, more preferably 30°C or higher and 70°C or lower, and even more preferably 40°C or higher and 60°C or lower. By carrying out the polycondensation reaction within this temperature range, polysilsesquioxane can be obtained as a wet gel containing water as a solvent therein.

[0051] Furthermore, by gradually increasing the pH using a pH adjuster while allowing the polysilsesquioxane condensation polymerization reaction to proceed, the carbon material or organic polymer can be dispersed more densely in the porous structure of the precursor gel, thereby further increasing the dispersibility of the carbon material in the three-dimensional structural framework of the porous silicon nitroxycarbide composite material.

[0052] The content of the surfactant in the acidic aqueous solution is preferably 0.1% by mass or more and 50% by mass or less, more preferably 0.5% by mass or more and 35% by mass or less, and even more preferably 2% by mass or more and 15% by mass or less.

[0053] The surfactant is not particularly limited, and examples thereof include nonionic surfactants and / or cationic surfactants. By appropriately selecting and using either or both of the nonionic surfactant and the cationic surfactant as the surfactant, it is possible to obtain the desired BET specific surface area and pore diameter.

[0054] Examples of nonionic surfactants include polyethylene glycol types (ether types, ester-ether types), polyhydric alcohol types, etc. Examples of polyethylene glycol-type nonionic surfactants include Pluronic (registered trademark) types. Examples of cationic surfactants include amine salt types, quaternary ammonium salt types, etc. By setting the surfactant content relative to the acidic aqueous solution to 0.1% by mass or more and 50% by mass or less, it is possible to form a porous polysilsesquioxane gel having a large BET specific surface area with developed mesopores to macropores.

[0055] The content of the pH adjuster in the acidic aqueous solution is preferably 5% by mass or more and 50% by mass or less, more preferably 5.5% by mass or more and 35% by mass or less, and even more preferably 6% by mass or more and 23% by mass or less. By setting the content of the pH adjuster in the acidic aqueous solution to 5% by mass or more and 50% by mass or less, a porous polysilsesquioxane gel having high skeletal strength and flexibility can be formed.

[0056] The pH adjuster is not particularly limited, but examples thereof include substances containing any one selected from urea, ammonia, and sodium hydroxide.

[0057] The acidic aqueous solution is not particularly limited, but examples thereof include aqueous solutions of hydrochloric acid, nitric acid, acetic acid, and the like.

[0058] The organic alkoxysilane is preferably represented by the following formula (1) or formula (2): By using an organic alkoxysilane represented by the following formula (1) or formula (2), porous silicon nitroxycarbide having a desired three-dimensional framework structure can be easily formed. １ -SiR ２ ｘ (OR ３ ) ３－ｘ ... (1) (wherein R １ is any group selected from a methyl group, an ethyl group, a vinyl group, and a phenyl group, and R ２ is a methyl group, R ３ represents a methyl group or an ethyl group. In the formula, the integer x is 0 or 1. ４-(SiR ５ ｙ (OR ６ ) ３－ｙ ) ２ ... (2) (wherein R ４ contains any group selected from a methylene group, an ethylene group, a hexylene group, a vinylene group, a phenylene group, and a biphenylene group, and R ５ is a methyl group, R ６ represents a methyl group or an ethyl group. In the formula, the integer y is 0 or 1.

[0059] Specific examples of the organic alkoxysilane represented by the above formula (1) include methyltrimethoxysilane, methyltriethoxysilane, dimethyldimethoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, methylethyldimethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, methylvinyldimethoxysilane, phenyltrimethoxysilane, phenyltriethoxysilane, and methylphenyldimethoxysilane. Specific examples of the organic alkoxysilane represented by the formula (2) include bis(trimethoxysilyl)methane, bis(triethoxysilyl)methane, bis(methyldimethoxysilyl)methane, bis(methyldiethoxysilyl)methane, 1,2-bis(trimethoxysilyl)ethane, 1,2-bis(triethoxysilyl)ethane, 1,2-bis(methyldimethoxysilyl)ethane, 1,2-bis(methyldiethoxysilyl)ethane, 1,6-bis(trimethoxysilyl)hexane, 1,6-bis(triethoxysilyl)hexane, 1,6-bis(methyldimethoxysilyl)hexane, 1,6-bis(methyldiethoxysilyl)hexane, Examples of suitable organic alkoxysilanes include 1,2-bis(trimethoxysilyl)ethene, 1,2-bis(triethoxysilyl)ethene, 1,2-bis(methyldimethoxysilyl)ethene, 1,2-bis(methyldiethoxysilyl)ethene, 1,4-bis(trimethoxysilyl)benzene, 1,4-bis(triethoxysilyl)benzene, 1,4-bis(methyldimethoxysilyl)benzene, 1,4-bis(methyldiethoxysilyl)benzene, 4,4'-bis(trimethoxysilyl)biphenyl, 4,4'-bis(triethoxysilyl)biphenyl, 4,4'-bis(methyldimethoxysilyl)biphenyl, and 4,4'-bis(methyldiethoxysilyl)biphenyl. The above-mentioned ethene derivatives include cis / trans geometric isomers, and either isomer can be used. The organic alkoxysilane used may be a single type or multiple types.

[0060] In this step (A), a carbon material or an organic polymer is further added to the acidic aqueous solution to form a gel containing the carbon material or the organic polymer. By adding the carbon material or the organic polymer during the sol-gel reaction of the alkoxysilane, the precursor formed in step (C) can be calcined in step (D) to arrange the carbon material at the nano level in a porous three-dimensional structural skeleton, thereby imparting excellent conductivity to the porous silicon nitroxycarbide, which is originally an insulator or semiconductor. By calcining in step (D), the organic polymer undergoes thermal decomposition and is retained in the porous silicon nitroxycarbide as low-crystalline nanocarbon, making it possible to impart conductivity.

[0061] In the step (A), the carbon material or organic polymer is preferably added to the acidic aqueous solution so that the mass ratio of the carbon material or organic polymer to the organic alkoxysilane is 2.5 to 50:97.5 to 50. The mass ratio of the carbon material or organic polymer to the organic alkoxysilane is more preferably 3 to 30:97 to 70, and even more preferably 5 to 20:95 to 80.

[0062] By setting the mass ratio of the carbon material or organic polymer to the organic alkoxysilane within the above range, it is possible to achieve both a larger BET specific surface area and higher electrical conductivity. When the amount of the carbon material or organic polymer added is equal to or less than the amount of the organic alkoxysilane added, separation from the sol-gel reaction system is suppressed, and the formation of a gel composed of polysilsesquioxane can be promoted.

[0063] The carbon material is not particularly limited, and may be composed of one or more selected from, for example, carbon black, carbon nanofiber, carbon nanotube, and low-crystalline nanocarbon. Among these, from the viewpoints of realizing high conductivity and manufacturability, the carbon material is preferably carbon black.

[0064] The organic polymer is not particularly limited, but may be composed of one or more selected from, for example, phenolic resin, polystyrene, and polydivinylbenzene.

[0065] [Step (B)] In step (B), the gel obtained in step (A) is washed with alcohol. The alcohol used for washing is not particularly limited, but examples thereof include methanol, ethanol, 1-propanol, and 2-propanol. This allows unnecessary surfactants to be removed from the acidic aqueous solution, and also allows the water in the acidic aqueous solution to be replaced with alcohol.

[0066] After washing with alcohol, the solvent may be replaced with a hydrocarbon solvent such as hexane or heptane. In step (B), water, which is a high surface tension solvent, is replaced with alcohol or a hydrocarbon solvent, which is a low surface tension solvent, and this can suppress network contraction in the drying step at room temperature and normal pressure in step (C) described below, making it easier to form a porous gel structure.

[0067] [Step (C)] In step (C), the washed gel is dried to form a porous silicon nitroxycarbide precursor that will become porous silicon nitroxycarbide in a subsequent step. Examples of methods that can be used in step (C) include supercritical drying using carbon dioxide at 80°C and 14 MPa, drying at room temperature and atmospheric pressure, and vacuum drying at 20°C to 80°C. Among these, drying at room temperature and atmospheric pressure is preferred because it is inexpensive to produce and, when a polysilsesquioxane with high skeletal strength and flexibility is formed, it can produce a high-density porous silicon nitroxycarbide precursor with developed mesopores.

[0068] [Step (D)] In step (D), the porous silicon nitroxycarbide precursor containing the carbon material or organic polymer is calcined to obtain a composite material containing silicon nitroxycarbide (SiCNO) and a carbon material. In this step, carbon atoms are supplied from the organic groups of the polysilsesquioxane by the calcination, nitrogen atoms are supplied by supplying nitrogen gas to create a nitrogen atmosphere, and oxygen atoms are supplied from the precursor formed from the alkoxysilane, forming a silicon nitroxycarbide skeleton. At the same time, carbon atoms are also supplied to the skeleton from the carbon material or organic polymer dispersed at the nano level in the gel. The organic polymer undergoes thermal decomposition by the calcination, and is retained in the porous silicon nitroxycarbide as low-crystalline nanocarbon.

[0069] The firing can be carried out by a known conventional method without any particular limitation, but for example, firing is carried out by raising the temperature at a rate of 2.5°C per minute in a nitrogen gas atmosphere and maintaining the reached maximum temperature for a certain period of time. The maximum firing temperature is preferably 1100°C or higher and lower than 1450°C, more preferably 1200°C or higher and 1425°C or lower, and particularly preferably 1300°C or higher and 1400°C or lower.

[0070] The time for which the maximum temperature is maintained during firing can be determined appropriately based on the time effective for obtaining a porous silicon nitroxycarbide composite material. For example, 5 minutes to 16 hours is preferable, 10 minutes to 10 hours is more preferable, and 30 minutes to 3 hours is particularly preferable. Firing may be carried out in two or more stages. That is, in the first stage, firing is carried out for a certain period of time at a temperature lower than the maximum temperature, and then the temperature is raised again and firing is carried out. Firing may be carried out at atmospheric pressure. The nitrogen gas atmosphere may contain oxygen gas, inert gas, etc. in addition to nitrogen gas.

[0071] The firing can be carried out in a fixed-bed or fluidized-bed firing furnace, and the heating method and type of the firing furnace are not particularly limited as long as the furnace has the function of raising the temperature to a predetermined temperature. Examples of firing furnaces include a lead hammer furnace, a tunnel furnace, and a single furnace.

[0072] In step (D), a carbon material or an organic polymer may be further mixed with the porous silicon nitroxycarbide precursor and the mixture may then be calcined. When an organic polymer is mixed with the porous silicon nitroxycarbide precursor in step (D), similar to the case of mixing in step (A), thermal decomposition proceeds by calcination, and the organic polymer is retained in the porous silicon nitroxycarbide as low-crystalline nanocarbon.

[0073] [Particles containing noble metal] When the total mass of the electrode catalyst is taken as 100 mass%, the amount of the particles containing the noble metal is preferably 10 mass% or more and 60 mass% or less, more preferably 15 mass% or more and 60 mass% or less, and more preferably 30 mass% or more and 60 mass% or less. When the amount of the particles containing the noble metal is 10 mass% or more and 60 mass% or less, the catalytic function is well expressed and durability is good. The amount of the particles containing the noble metal can be calculated, for example, by alkali-melting the electrode catalyst, dissolving it in aqua regia, diluting it with ultrapure water, and then performing high-frequency induction heating optical emission spectroscopy (ICP).

[0074] The particles containing a noble metal are preferably composed of one selected from the group consisting of platinum (Pt), gold (Au), ruthenium (Ru), rhodium (Rh), palladium (Pd), iridium (Ir), platinum-cobalt alloy (PtCo), platinum-nickel alloy (PtNi), and platinum-ruthenium alloy (PtRu). Among these, from the viewpoint of high durability at high temperatures and high catalytic function, it is more preferable to be composed of one or more selected from the group consisting of platinum (Pt), platinum-cobalt alloy (PtCo), and platinum-nickel alloy (PtNi), and it is even more preferable to be composed of platinum (Pt) or platinum-cobalt alloy (PtCo).

[0075] The particles containing a noble metal are preferably nanoparticles containing a noble metal. The average particle size of the primary particles of the particles containing a noble metal is preferably 2 nm to 10 nm, more preferably 2.5 nm to 7 nm, and even more preferably 3 nm to 5 nm. When the average particle size of the primary particles of the particles containing a noble metal is 2 nm to 10 nm, good catalytic performance can be exhibited even with a small amount of noble metal.

[0076] The mass ratio of carbon (C) to silicon (Si) contained in the electrode catalyst ([C] / [Si]) is preferably 3.0 / 1.0 to 8.0 / 1.0, more preferably 3.0 / 1.0 to 7.5 / 1.0, and even more preferably 3.0 / 1.0 to 7.0 / 1.0. When the mass ratio of carbon (C) to silicon (Si) ([C] / [Si]) is 3.0 / 1.0 to 8.0 / 1.0, high conductivity is achieved while suppressing carbon corrosion and the like, thereby improving the durability of the catalytic cycle. Note that the carbon (C) in the above mass ratio refers to the sum of the carbon constituting the three-dimensional framework structure of the porous silicon nitroxycarbide and the carbon in the carbon material supported on the porous silicon nitroxycarbide.

[0077] The silicon (Si) content in the electrode catalyst can be calculated, for example, by inductively coupled plasma emission spectroscopy (ICP), and the carbon (C) content can be calculated by high-frequency combustion-infrared absorption spectroscopy.

[0078] [Electrode Catalyst Characteristics] The electrode catalyst of this embodiment has a conductivity of 0.1 S / cm or more, preferably 1 S / cm or more, more preferably 5 S / cm or more, and even more preferably 10 S / cm or more. The conductivity may be 100 S / cm or less, 70 S / cm or less, or 50 S / cm or less. The higher the conductivity of the porous silicon nitroxycarbide, the better the fuel cell electrode catalyst can be provided. However, if the amount of carbon material that contributes to improving conductivity is too high, corrosion of the carbon component may progress during the catalytic cycle, resulting in reduced durability.

[0079] <Method for Manufacturing Electrode Catalyst> As shown in FIG. 1 , the method for manufacturing an electrode catalyst according to this embodiment includes a gel-forming step (step (A)), a washing step (step (B)), a porous silicon nitroxycarbide precursor-forming step (step (C)), a calcination step (step (D)), and a mixing step (step (E)). Note that, provided that the electrode catalyst according to this embodiment is obtained, other steps may be performed before or after each step. In the method for manufacturing an electrode catalyst according to this embodiment, examples of the gel-forming step (step (A)), the washing step (step (B)), the porous silicon nitroxycarbide precursor-forming step (step (C)), and the calcination step (step (D)) include steps (A), (B), (C), and (D) in the method for manufacturing a porous silicon nitroxycarbide composite material described above, respectively. That is, the method for manufacturing an electrode catalyst according to this embodiment may include the method for manufacturing a porous silicon nitroxycarbide composite material according to this embodiment, and the following mixing step (step (E)) using the manufactured porous silicon nitroxycarbide composite material.

[0080] [Step (E)] In step (E), a dispersion containing a noble metal-containing colloid and aqueous hydrogen peroxide is mixed with the porous silicon nitroxycarbide composite material to obtain an electrode catalyst containing noble metal-containing particles. The noble metal-containing colloid is a dispersion of noble metal-containing particles in a liquid, and the dispersion containing a noble metal-containing colloid is a solution containing the noble metal-containing colloid and aqueous hydrogen peroxide. The noble metal-containing colloid and the dispersion containing the noble metal-containing colloid and aqueous hydrogen peroxide can be prepared by known, conventional methods.

[0081] The mixing ratio of the dispersion containing a colloid containing a precious metal and the porous silicon nitroxycarbide composite material is, for example, preferably such that the mass of the supported precious metal is 10 mass % or more and 60 mass % or less, more preferably 20 mass % or more and 55 mass % or less, and even more preferably 30 mass % or more and 50 mass % or less, relative to the total mass of the electrode catalyst.

[0082] The colloid containing a noble metal is preferably composed of colloids of one or more metals selected from the group consisting of platinum (Pt), gold (Au), ruthenium (Ru), rhodium (Rh), palladium (Pd), osmium (Os), and iridium (Ir). Among these, it is more preferable to be composed of one or more metals selected from the group consisting of platinum (Pt) colloid, platinum-cobalt alloy (PtCo) colloid, and platinum-nickel alloy (PtNi) colloid, and it is even more preferable to be composed of platinum (Pt) colloid or platinum-cobalt alloy (PtCo) colloid.

[0083] In step (E), stirring the mixture of the noble metal-containing colloid, the hydrogen peroxide-containing dispersion, and the porous silicon nitroxycarbide composite material supports the noble metal-containing colloid, yielding an electrode catalyst containing noble metal-containing particles. After leaving the mixture for a predetermined period of time, the solid and liquid phases are separated. To promote solid-liquid separation, the mixture may be cooled. The solids can be washed using known, conventional methods and conditions. The washing liquid used for washing is not particularly limited, but may be, for example, water, preferably ultrapure water. This removes ions such as chloride ions from the solids.

[0084] In the above step (E), particles containing a noble metal are dispersed and supported on the porous silicon nitroxycarbide composite material. The particles containing a noble metal are preferably composed of one or more selected from the group consisting of platinum (Pt), gold (Au), ruthenium (Ru), rhodium (Rh), palladium (Pd), osmium (Os), and iridium (Ir). Among these, from the viewpoint of high durability at high temperatures and high catalytic function, particles containing one or more selected from the group consisting of platinum (Pt), platinum-cobalt alloy (PtCo), and platinum-nickel alloy (PtNi) are more preferred, and particles containing platinum (Pt) or platinum-cobalt alloy (PtCo) are even more preferred. Furthermore, it is preferable to support nanoparticles containing a noble metal on the porous silicon nitroxycarbide composite material.

[0085] [Fuel Cell Electrode and Fuel Cell] The fuel cell electrode according to this embodiment has a catalyst layer containing the electrode catalyst. The fuel cell electrode typically has the electrode catalyst layer and a gas diffusion layer. The fuel cell electrode may be a fuel cell negative electrode (anode) or a fuel cell positive electrode (cathode). When the fuel cell electrode is a fuel cell negative electrode, the fuel cell negative electrode has an anode catalyst layer to which a fuel such as hydrogen is supplied, and a first gas diffusion layer. When the fuel cell electrode is a fuel cell positive electrode, the fuel cell positive electrode has a cathode catalyst layer to which an oxygen-containing gas such as air is supplied, and a second gas diffusion layer.

[0086] The fuel cell according to this embodiment includes the above-described fuel cell electrode. The fuel cell includes the fuel cell electrode and an electrolyte layer. Typically, the fuel cell includes a fuel cell negative electrode (anode), a fuel cell positive electrode (cathode), an electrolyte layer disposed therebetween, a first separator disposed on the fuel cell negative electrode opposite the electrolyte layer, and a second separator disposed on the fuel cell positive electrode opposite the electrolyte layer. In this case, the anode catalyst layer is disposed between the electrolyte layer and the first gas diffusion layer, and the cathode catalyst layer is disposed between the electrolyte layer and the second gas diffusion layer.

[0087] The above-described fuel cell electrode and fuel cell have a catalyst layer containing the above-described electrode catalyst, thereby achieving high conductivity while maintaining a large BET specific surface area. In addition, the nano-level arrangement of carbon material in silicon nitroxycarbide having a porous three-dimensional structure skeleton reduces the possibility of oxidative degradation of the carbon material, which has been a conventional problem, for example, in high-temperature and high-humidity environments, thereby achieving excellent durability as a fuel cell electrode and a fuel cell.

[0088] Although the embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as defined in the claims.

[0089] Examples of the present invention will be described below. The present invention is not limited to the examples shown below. "Example *" is an embodiment of the present invention, and "Comparative Example *" is an embodiment of the prior art. Values ​​in the tables mean "parts by weight" unless otherwise specified.

[0090] Synthesis Example 1 Synthesis of Porous Silicon Nitroxycarbide Composite Material 6 g of a 5 mM aqueous acetic acid solution (Kanto Chemical Co., Inc.), 0.8 g of Pluronic (registered trademark) F-127 (BASF Corporation), 0.5 g of urea (Kanto Chemical Co., Inc.), and 0.24 g of Ketjen Black (Lion Specialty Chemicals Corporation, product name "EC-600") were placed in a vial and stirred at room temperature for 10 minutes. 5 g of methyltrimethoxysilane (Kanto Chemical Co., Inc.) was added thereto, and the mixture was stirred at room temperature for 30 minutes.

[0091] The mixture was then reacted at 60°C for four days to obtain a wet gel. The resulting wet gel was washed with methanol (Kanto Chemical Co., Ltd.) and dried at room temperature and atmospheric pressure for three days, and then further dried at 80°C and atmospheric pressure for six hours to obtain 3.5 g of porous silicon nitroxycarbide precursor 1. 1 g of this porous silicon nitroxycarbide precursor was mixed with 0.5 g of Ketjen Black (Lion Specialty Chemicals Co., Ltd., product name "Carbon ECP"), and then charged into a tubular furnace. The mixture was heated to 1400°C at a rate of 2.5°C / min in a nitrogen atmosphere and fired for two hours to obtain porous silicon nitroxycarbide composite material SC1.

[0092] Synthesis Example 2 A porous silicon nitroxycarbide composite material SC2 was obtained in the same manner as in Synthesis Example 1, except that 0.4 g of Ketjen black was added during firing.

[0093] Synthesis Example 3 A porous silicon nitroxycarbide composite material SC3 was obtained in the same manner as in Synthesis Example 1, except that 0.2 g of Ketjen black was added during firing.

[0094] Comparative Synthesis Example 1 A porous silicon nitroxycarbide composite material cSC1 was obtained in the same manner as in Synthesis Example 1, except that 0.1 g of Ketjen black was added during firing.

[0095] Example 1 Synthesis of an electrode catalyst containing platinum nanoparticles 0.43 g of chloroplatinic acid hexahydrate was dissolved in 60 mL of ultrapure water, and 3.1 g of sodium bisulfite was added to the solution to allow a reduction reaction to proceed. The solution was then diluted with 280 mL of ultrapure water. Next, a 5% aqueous solution of sodium hydroxide was added to adjust the pH to approximately 5, while 24 mL of 35% hydrogen peroxide was added dropwise to obtain a dispersion containing platinum colloid. Subsequently, an aliquot of the colloidal dispersion was taken so that the amount of platinum (Pt) after loading was 45 mass% relative to the total amount of the electrode catalyst including the carrier. 0.4 g of the porous silicon nitroxycarbide composite material SC1 obtained in Synthesis Example 1 was added as a carrier, and the mixture was mixed at 90°C for 3 hours. After cooling, solid-liquid separation was performed, and the obtained powder (solid content) was thoroughly washed with ultrapure water to remove chloride ions, and then dried at 80°C for 12 hours to obtain electrode catalyst A in which platinum was supported on the surface of porous silicon nitroxycarbide composite material SC1.

[0096] Example 2 Electrode catalyst B was obtained in the same manner as in Example 1, except that the porous silicon nitroxycarbide composite material SC2 obtained in Synthesis Example 2 was used. A transmission electron microscope image of electrode catalyst B is shown in Figure 6. It was confirmed that platinum nanoparticles with a particle diameter of approximately 3 nm were supported on the porous silicon nitroxycarbide composite material.

[0097] Example 3 An electrode catalyst C was obtained in the same manner as in Example 1, except that the porous silicon nitroxycarbide composite material SC3 obtained in Synthesis Example 3 was used.

[0098] Example 4 Electrode catalyst D was obtained in the same manner as in Example 2, except that the colloidal dispersion was dispensed so that the amount of platinum (Pt) after loading was 30 mass % based on the total amount of the electrode catalyst including the carrier.

[0099] Example 5 An electrode catalyst E was obtained in the same manner as in Example 2, except that the colloidal dispersion was dispensed so that the amount of platinum (Pt) after loading was 60 mass % based on the total amount of the electrode catalyst including the carrier.

[0100] Comparative Example 1 An electrode catalyst F was obtained in the same manner as in Example 1, except that the porous silicon nitroxycarbide composite material cSC1 obtained in Comparative Synthesis Example 1 was used.

[0101] Comparative Example 2 Pt / CB (Tanaka Kikinzoku K.K., TEC10E50E, Pt loading 46 wt %) was used as the cathode catalyst.

[0102] Measurements were carried out for the porous silicon nitroxycarbide composite materials SC1 to SC3 and cSC1, which are the samples of Synthesis Examples 1 to 3 and Comparative Synthesis Example 1, and the electrode catalysts A to F, which are the samples of Examples 1 to 5 and Comparative Example 1, and the Pt / CB of Comparative Example 2, for the following measurement items. The results are shown in Table 1.

[0103] [Elemental Composition Ratios] [Composition Analysis of Porous Silicon Nitroxycarbide Composite Materials] Porous silicon nitroxycarbide composite materials SC1 to SC3 and cSC1 were fixed to carbon tape, and the elemental ratios of [C] / [Si], [O] / [Si], and [N] / [Si] were calculated from the elemental contents of Si, C, O, and N obtained by SEM-EDS (Energy Dispersive X-ray Spectroscopy).

[0104] [Measurement of BET specific surface area, pore volume, and pore diameter] 0.04 g of powder of porous silicon nitroxycarbide composite materials SC1 to SC3 and cSC1 was weighed out and placed in a sample tube, and pretreated by vacuum drying for 6 hours at 100° C. After pretreatment, nitrogen was adsorbed onto the sample at −196° C. while changing the relative pressure using a specific surface area / pore size distribution device (Microtrac BEL Corporation: device name "BELSORP-mini II").

[0105] [Measurement of Electrical Conductivity] Porous silicon nitroxycarbide composite materials SC1 to SC3 and cSC1 were introduced into a powder resistivity measurement system (manufactured by Mitsubishi Chemical Analytech Co., Ltd.: device name "MCP-PD51"), and the samples were pressurized using the attached hydraulic pump. After the pressure reached 12 kN, the resistivity was measured using a resistivity meter (manufactured by Mitsubishi Chemical Analytech Co., Ltd.: device name "Loresta GX"), and the conductivity was calculated from the resistivity using the following formula (1): Conductivity (S / cm) = (Resistivity (Ω cm)) －１ ...(1)

[0106] [Particle diameter D ５０ Measurement of particle diameter D of porous silicon nitroxycarbide composite materials SC1 to SC3 and cSC1 ５０ was measured using a laser diffraction particle size distribution measuring device (Horiba, Partica LA-960V2) in accordance with JIS Z8825-1:2013.

[0107] [Measurement of Pt loading rate] Examples 1 to 5, 50DA to F of Comparative Example 1, and Pt / CB of Comparative Example 2 were subjected to alkali fusion using anhydrous sodium carbonate and sodium peroxide. Then, the Pt loading rate was dissolved in aqua regia, diluted with ultrapure water to a specified concentration, and calculated by high-frequency induction heating optical emission spectroscopy (ICP; Model ICPE-9820 manufactured by Shimadzu Corporation).

[0108] [Evaluation of catalytic performance using a rotating electrode] (Electrode preparation) A glassy carbon (GC) electrode with a diameter of 5 mm was polished using alumina paste and then ultrasonically cleaned using ultrapure water. Electrode catalysts A to F of Examples 1 to 5 and Comparative Example 1 and Pt / CB of Comparative Example 2 were added to a 99% by volume aqueous ethanol solution and dispersed using an ultrasonic homogenizer. This was dropped onto a GC disk and dried at room temperature for 12 hours. After drying, a 5% Nafion (registered trademark) solution was dropped onto the electrode catalyst on the GC disk to a dry film thickness of 50 nm and then dried at room temperature for 12 hours.

[0109] (CV Measurement) Electrode evaluation was performed using an electrochemical measurement system (HZ-5000, manufactured by Hokuto Denko Corporation). After purging a 0.1 M aqueous solution of perchloric acid with nitrogen gas for 30 minutes, cleaning was performed 50 times using a reversible hydrogen electrode (RHE) as the reference electrode at a potential range of 0.05 to 1.2 V and a sweep rate of 150 mV / s. Cyclic voltammetry (CV) measurements were then performed at a potential range of 0.05 to 1.0 V and a sweep rate of 100 mV / s. The CV measurement results for electrode catalyst B are shown in Figure 7. Analysis of the electrochemically active surface area (ECSA) was performed using the hydrogen adsorption wave observed at 0.4 V or less. The method for analyzing the electrochemically active surface area (ECSA) is based on the method described in Non-Patent Document A below. [Non-Patent Document A] FC-Cubic Technology Research Association: Electrocatalyst RDE Evaluation Method, July 21, 2023, ver. 1.2.1.

[0110] (Evaluation of oxygen reduction activity) After purging the electrolyte with oxygen gas for at least one hour, linear sweep voltammetry (LSV) was performed. Data was acquired under eight conditions: temperature 25°C, potential range 0.25 to 1.00 V, sweep rate 5 mV / s, and rotation speed increasing in 250 rpm increments from 1000 rpm to 2750 rpm. The results were analyzed using a Koutecky-Levich plot to obtain the mass activity (A / g-Pt) value at 0.85 V. The mass activity analysis method used was the same as that described in Non-Patent Document A above.

[0111] (Start / Stop Durability Evaluation) After purging the above electrolyte with nitrogen gas for 30 minutes, the potential range of 1.0 to 1.5 V was swept 500 times, and CV measurement was performed in the potential range of 0.05 to 1.0 V. This measurement procedure constituted one set, and a test was performed for 56,000 cycles. The results are shown in Table 1.

[0112] [Fabrication of Single Fuel Cell] (Fabrication of Anode Catalyst Ink) 0.45 g of platinum (Pt)-loaded carbon black (Pt / CB, Tanaka Kikinzoku Co., Ltd., TEC10E50E, Pt loading 46 wt%) and a polymer electrolyte (Du Pont, Nafion (registered trademark) DE521) were mixed at a volume ratio of 1.0. This mixture, 2.5 g of ethanol, 2 g of water, and zirconia balls (diameter 5 mm) were placed in a zirconia pot and mixed for 60 minutes in a planetary ball mill (Fritsch, P-6). The mixture obtained by mixing in this ball mill is hereinafter referred to as the anode catalyst ink.

[0113] (Preparation of Cathode Catalyst Ink) Electrode catalyst B or Pt / CB and a polymer electrolyte (Nafion (registered trademark) DE521, manufactured by Du Pont) were mixed at a volume ratio of 0.7. This mixture, 2.5 g of ethanol, 2 g of water, and zirconia balls (diameter 5 mm) were placed in a zirconia pot and mixed for 60 minutes in a planetary ball mill (P-6, manufactured by Fritsch).

[0114] (Fabrication of Membrane Electrode Assembly (MEA)) The anode catalyst layer and the cathode catalyst layer were formed by spray coating a polymer electrolyte membrane (Nafion NR212, manufactured by Du Pont) with a platinum coating weight of 0.5 mg / cm2. ２ , the platinum content of the cathode is 0.3 mg / cm ２ The anode catalyst ink and the cathode catalyst ink were applied so that the anode catalyst layer and the cathode catalyst layer were coated on the cathode catalyst ink ...

[0115] In the above CCM, gas diffusion layers (GDL, manufactured by SGL, 22BB) were overlaid on both sides of each catalyst layer, and a cathode catalyst layer and an anode catalyst layer were laminated on the polymer electrolyte membrane so as to face each other, to obtain a membrane electrode assembly (MEA). A single cell was assembled using the above MEA and placed in a power generation evaluation device (manufactured by Panasonic Production Technology).

[0116] [Evaluation of Single Fuel Cell (80°C)] (IV Characteristics) Hydrogen gas was supplied to the anode side of a single cell obtained using electrode catalyst B or Pt / CB as the cathode catalyst, and oxygen gas was supplied to the cathode side. The flow rates were set so that the hydrogen gas utilization rate was 70% and the oxygen gas utilization rate was 40%. The anode and cathode gases were each humidified using an external humidifier before being supplied to the single cell. The temperature of the single cell was adjusted to 80°C, and the humidity of the supplied gas was adjusted to a relative humidity of 80% RH. Power was generated within an applied current range in which the voltage of this single cell did not fall below 0.4 V, and the IV characteristics were evaluated.

[0117] (Measurement of Start / Stop Durability) Hydrogen gas was introduced into the anode side of a single cell, and nitrogen gas was introduced into the cathode side. A start / stop durability test of 5,000 cycles was performed at a temperature of 80°C, a relative humidity of 80% RH, and a potential range of 1.0 V to 1.5 V, and the rate of change in electrochemically effective surface area (ECSA) was measured. ECSA was calculated using cyclic voltammetry (CV) by sweeping six times at a temperature of 80°C, a relative humidity of 80% RH, and a sweep potential of 0.05 V to 1.0 V, using the quantity of hydrogen adsorbed electricity in the sixth sweep. The rate of change in ECSA for electrode catalyst B is shown in Figure 8.

[0118]

[0119] (Discussion) As shown in Table 1, in Examples 1 to 5, the BET specific surface area of ​​the porous silicon nitroxycarbide composite material used as the carrier was 150 m ２ / g or more and a conductivity of 1.0 S / cm or more, demonstrating high conductivity while maintaining a large BET specific surface area. Furthermore, as a result of catalyst performance evaluation using a rotating electrode, it was found that Examples 1 to 5 had a mass activity of 451 (A / g-Pt) or more, a high current per unit mass of platinum (Pt), and exhibited high oxygen reduction activity. Furthermore, the ECSA retention rate after durability testing was 75% or more, demonstrating excellent durability. When electrode catalyst B was used as the cathode catalyst for a single fuel cell, it was found that the mass activity of 1.0 A / cm ２The result of the durability test showed that the ECSA maintenance rate was 70%, demonstrating excellent durability as a single fuel cell.

[0120] In Comparative Example 1, the conductivity of the porous silicon nitroxycarbide composite material was as low as 0.9 S / cm, and as a result, the ECSA was very low in the catalyst performance evaluation using a rotating electrode, making it impossible to calculate the mass activity. In Comparative Example 2, the mass activity was 450 (A / g-Pt), but the ECSA retention rate after the durability test was low at 55%, making it inferior to the Examples. When Pt / CB was used as the cathode catalyst for the single fuel cell, the ECSA retention rate was 1.0 A / cm. ２ Although excellent power generation performance was exhibited with a voltage of 0.66 V at times, the durability test results showed that the ECSA maintenance rate was 55%, indicating that the durability as a single fuel cell was inferior to that of the Examples.

[0121] The electrode catalyst, fuel cell electrode, fuel cell, and method for producing the porous silicon nitroxycarbide composite material of the present invention can provide a porous silicon nitroxycarbide composite material having both a larger BET specific surface area and high electrical conductivity, and when used as an electrode material for the catalyst layer of a fuel cell electrode, can realize a fuel cell with high power generation efficiency, and therefore have industrial applicability.

Claims

1. A porous silicon nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material, and particles containing a noble metal supported on the porous silicon nitroxycarbide composite material, wherein the BET specific surface area of ​​the porous silicon nitroxycarbide composite material is 100 m ２ / g or more 400m ２ / g or less, and the conductivity of the porous silicon nitroxycarbide composite material is 1.0 S / cm or more and 25 S / cm or less.

2. The electrode catalyst according to claim 1, wherein the amount of particles containing the noble metal carried is 10 mass % or more and 60 mass % or less when the total mass of the electrode catalyst is taken as 100 mass %.

3. The electrode catalyst according to claim 1 or 2, wherein the content of the carbon material is 5% by mass or more and 50% by mass or less.

4. The electrode catalyst according to claim 1 or 2, wherein the carbon material is composed of one or more selected from the group consisting of carbon black, carbon nanofibers, carbon nanotubes, and low-crystalline nanocarbons.

5. The electrode catalyst according to claim 1 or 2, wherein the particles containing the noble metal are composed of one or more types selected from the group consisting of platinum (Pt), platinum-cobalt alloy (PtCo), and platinum-nickel alloy (PtNi).

6. The total pore volume of the porous silicon nitroxycarbide composite material is 1.3 cm ３ / g or more 2.5cm ３ The electrode catalyst according to claim 1 or 2, wherein the surface area of ​​the electrode catalyst is 100 μm / g or less.

7. The electrode catalyst according to claim 1 or 2, wherein the pore diameter of the porous silicon nitroxycarbide composite material is 10 nm or more and 500 nm or less.

8. An electrode catalyst according to claim 1 or 2, wherein the mass ratio ([C] / [Si]) of carbon (C) to silicon (Si) contained in the porous silicon nitroxycarbide composite material is 3.0 or more and 8.0 or less.

9. An electrode catalyst according to claim 1 or 2, wherein the mass ratio of oxygen (O) to silicon (Si) contained in the porous silicon nitroxycarbide composite material ([O] / [Si]) is 0.2 or more and 1.5 or less.

10. An electrode catalyst according to claim 1 or 2, wherein the mass ratio ([N] / [Si]) of nitrogen (N) to silicon (Si) contained in the porous silicon nitroxycarbide composite material is 0.05 or more and 2.0 or less.

11. A fuel cell electrode having a layer containing the electrode catalyst according to claim 1 or 2.

12. A fuel cell comprising the fuel cell electrode according to claim 11.

13. A method for producing an electrocatalyst, comprising: (A) a step of adding an organic alkoxysilane to an acidic aqueous solution containing a surfactant and a pH adjuster, and further adding a carbon material or an organic polymer, to form a gel containing the carbon material or the organic polymer through a sol-gel reaction of the organic alkoxysilane; (B) a step of washing the gel with alcohol; (C) a step of drying the washed gel to form a porous silicon nitroxycarbide precursor; (D) a step of calcining the porous silicon nitroxycarbide precursor in a nitrogen-containing atmosphere to obtain a porous silicon nitroxycarbide composite material containing silicon nitroxycarbide (SiCNO) and a carbon material; and (E) a step of mixing the porous silicon nitroxycarbide composite material with a dispersion containing a noble metal colloid and hydrogen peroxide water to obtain an electrocatalyst containing noble metal particles.

14. The method for producing an electrode catalyst according to claim 13, wherein in step (D), the porous silicon nitroxycarbide precursor is calcined at 1100°C or higher and lower than 1450°C.

15. The method for producing an electrode catalyst according to claim 13 or 14, wherein the organic alkoxysilane is represented by the following formula (1) or formula (2): １ -SiR ２ ｘ (OR ３ ) ３－ｘ ...(1) (in the formula R １ is any group selected from a methyl group, an ethyl group, a vinyl group, and a phenyl group, and R ２ is a methyl group, R ３ represents a methyl group or an ethyl group. In the formula, the integer x is 0 or 1. ４ -(SiR ５ ｙ (OR ６ ) ３－ｙ ) ２ ...(2) (in the formula R ４ contains any group selected from a methylene group, an ethylene group, a hexylene group, a vinylene group, a phenylene group, and a biphenylene group, and R ５ is a methyl group, R ６ represents a methyl group or an ethyl group. In the formula, the integer y is 0 or 1.

16. The method for producing an electrode catalyst according to claim 13 or 14, wherein the carbon material is one or more selected from the group consisting of carbon black, carbon nanofiber, carbon nanotube, and low-crystalline nanocarbon.

17. The method for producing an electrode catalyst according to claim 13 or 14, wherein the colloid containing a noble metal is composed of one or more colloids selected from the group consisting of platinum (Pt) colloid, platinum-cobalt alloy (PtCo) colloid, and platinum-nickel alloy (PtNi) colloid.

18. The method for producing an electrode catalyst according to claim 13 or 14, wherein the mass ratio of the carbon material or the organic polymer to the organic alkoxysilane is 2.5-50:97.5-50.

19. The method for producing an electrode catalyst according to claim 13 or 14, wherein the organic polymer is one or more selected from the group consisting of phenolic resin, polystyrene, and polydivinylbenzene.

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