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WO2008058199A1 - Couches d'électrocatalyseurs pour piles à combustible et leurs procédés de fabrication - Google Patents

Couches d'électrocatalyseurs pour piles à combustible et leurs procédés de fabrication Download PDF

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Publication number
WO2008058199A1
WO2008058199A1 PCT/US2007/083954 US2007083954W WO2008058199A1 WO 2008058199 A1 WO2008058199 A1 WO 2008058199A1 US 2007083954 W US2007083954 W US 2007083954W WO 2008058199 A1 WO2008058199 A1 WO 2008058199A1
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WO
WIPO (PCT)
Prior art keywords
electrocatalyst
furfuryl alcohol
cathode
layer
anode
Prior art date
Application number
PCT/US2007/083954
Other languages
English (en)
Inventor
Miho S. Hall
Siyu Ye
Original Assignee
Bdf Ip Holdings Ltd.
Ballard Material Products Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bdf Ip Holdings Ltd., Ballard Material Products Inc. filed Critical Bdf Ip Holdings Ltd.
Priority to CA002668895A priority Critical patent/CA2668895A1/fr
Publication of WO2008058199A1 publication Critical patent/WO2008058199A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/8605—Porous electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/88—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/92—Metals of platinum group
    • H01M4/921—Alloys or mixtures with metallic elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1004—Fuel cells with solid electrolytes characterised by membrane-electrode assemblies [MEA]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells

Definitions

  • the present disclosure generally relates to electrocatalyst layers and electrochemical fuel cells, and to methods of making electrocatalyst layers for electrochemical fuel cells.
  • Electrochemical fuel cells convert reactants, namely fuel and oxidant fluid streams, to generate electric power and reaction products.
  • Electrochemical fuel cells generally employ a membrane electrode assembly (MEA) disposed between two separator plates that are substantially impermeable to the reactant fluid streams.
  • the plates typically act as current collectors and provide support for the MEA.
  • the plates may have reactant channels formed therein and act as flow field plates providing access for the reactant fluid streams, such as hydrogen gas and air, to the MEA and providing for the removal of reaction products formed during operation of the fuel cell.
  • a number of fuel cells are electrically coupled in series to form a fuel cell stack.
  • PEM polymer electrolyte membrane
  • MEA solid polymer electrolyte or ion-exchange membrane
  • the membrane acts both as a barrier for isolating the reactant streams from each other and as an electrical insulator between the two electrodes.
  • a typical commercial PEM is a sulfonated perfluorocarbon membrane sold by E.I. Du Pont de Nemours and Company under the trade designation Nafion ® .
  • the MEA further comprises two electrodes, each electrode disposed on opposing surfaces of the ion-exchange membrane.
  • Each electrode typically comprises a porous, electrically conductive substrate, such as carbon fiber paper or carbon cloth, which provides structural support to the membrane and serves as a gas diffusion layer.
  • the gas diffusion layer also contains a sublayer of carbon particles with an optional binder.
  • the electrodes further comprise an electrocatalyst, disposed between the membrane and the gas diffusion layers, which is typically a precious metal composition (e.g., platinum metal black or an alloy thereof) and may be provided on a suitable electrocatalyst support (e.g., fine platinum particles supported on a carbon black support).
  • the electrocatalyst may also contain an ionomer to improve proton conduction through the electrode.
  • the electrode typically contains a hydrophobic material such as polytetrafluoroethylene (PTFE) to impart water management properties to the electrode.
  • PTFE polytetrafluoroethylene
  • Water management is a key property of the electrode because water is produced during fuel cell operation. Without adequate water removal, the product water may accumulate, creating performance losses due to increased mass transport losses, particularly at high current densities where a relatively large amount of water is produced.
  • PTFE has been limited when used in electrocatalyst compositions containing an ionomer because PTFE is hydrophobic in nature and does not uniformly mix with the ionomer, which is hydrophilic.
  • the high sintering temperatures required for PTFE to "flow" into the fluid diffusion layer and/or the electrocatalyst damages or destroys most ionomers.
  • membrane electrode assembly comprises: an anode having an anode gas diffusion layer and an anode electrocatalyst layer; a cathode having a cathode gas diffusion layer and a cathode electrocatalyst layer; and a proton exchange membrane disposed between the anode and the cathode; wherein at least one of the anode electrocatalyst layer and the cathode electrocatalyst layers comprises polyfurfuryl alcohol.
  • the cathode electrocatalyst layer comprises a platinum alloy catalyst and an ionomer. In other embodiments, the distribution of polyfurfuryl alcohol is non-uniform.
  • a method of making an electrode for an electrochemical fuel cell comprises the steps of: applying an electrocatalyst composition to a sheet material; adding monomeric furfuryl alcohol to the electrocatalyst composition; and polymerizing the monomeric furfuryl alcohol after adding monomeric furfuryl alcohol and applying the catalyst composition.
  • FIG. 1 is a schematic illustration of a membrane electrode assembly.
  • Figure 2 is a graph showing polarization curves for fuel cells having a platinum electrocatalyst and a platinum-cobalt alloy electrocatalyst for the cathode electrode, both in combination with a Nafion ® ionomer.
  • FIG 1 shows a schematic illustration of an exemplary membrane electrode assembly 10 (“MEA").
  • MEAs typically include electrocatalyst layers 12,14 disposed between gas diffusion layers 16,18 (“GDL”) and a proton exchange membrane 20 (“PEM”).
  • Electrocatalyst layers 12,14 usually contain an electrocatalyst, such as a noble metal, non-noble metal, and/or alloys thereof, combined with an ionomer to increase proton conductivity within the electrocatalyst layers.
  • GDLs 16,18 typically includes a substrate 22,24, such as carbon fiber paper, and an optional sublayer 26,28, such as a layer comprising carbonaceous particles and a binder, for example, PTFE and/or an ionomer.
  • electrocatalyst layer an important property of the electrocatalyst layer is water management because it has a large influence on performance. If the electrocatalyst layer cannot adequately remove excess product water, fuel cell performance will be adversely affected due to excessive mass transport losses, particularly when operating with air as the oxidant at high current densities where large amounts of water are produced. In particular, it has been found that certain electrocatalysts, such as platinum-cobalt alloy electrocatalysts, have lower kinetic losses than pure platinum catalysts. This performance gain is not realized, however, with increasing current densities.
  • the anode electrocatalyst was platinum on a graphite support and the loading was 0.1 mg Pt/cm 2 .
  • the membrane was NRE211, a Nafion ® -based polymer electrolyte membrane supplied by E.I. Du Pont de Nemours and Company.
  • the cathode electrocatalyst for one of the MEAs was platinum on a graphite support and mixed with a Nafion ® binder, while the cathode electrocatalyst for the other MEA was a platinum- cobalt alloy on a graphite support and mixed with a Nafion ® binder. Both of these cathodes had a loading of 0.4 mg Pt/cm 2 . At 1.0 A/cm 2 , the testing conditions were as follows:
  • electrocatalyst layers having a platinum-cobalt alloy tend to have higher mass transport loss at high current densities than electrocatalyst layers containing pure platinum due to water retention.
  • incorporation of a hydrophobic additive, which is compatible with the catalyst layer components, into such an electrocatalyst layer decreases water retention and enhances fuel cell performance at high current densities.
  • Polyfurfuryl alcohol (PFA) has been found to be a particularly suitable hydrophobic additive for electrocatalyst layers for electrochemical fuel cells because it polymerizes at a temperature below the decomposition temperature of most ionomers, such as Nafion ® .
  • the literature has shown that Nafion ® membranes for direct methanol fuel cells have been made by in-situ acid-catalyzed polymerization of furfuryl alcohol within Nafion ® structures.
  • PFA when PFA is employed in the electrocatalyst layer having an ionomer, PFA imparts at least partial hydrophobicity within its relatively hydrophilic ionomer network, thus altering the water management properties of the electrocatalyst layer. Furthermore, ion conductivity should not be affected if PFA exists in the appropriate amounts. PFA may also enhance the tensile and/or adhesive strength between the electrocatalyst and the ionomer in the electrocatalyst layer (thereby decreasing dimensional change of the electrocatalyst layer due to hydration/dehydration), and may prevent cracks from forming on the surface of the electrocatalyst layer.
  • PFA is uniformly distributed within the electrocatalyst layer. In other embodiments, PFA is non-uniformly distributed within the electrocatalyst layer.
  • concentration of PFA through the thickness of the electrocatalyst layer may be varied in the z-direction (i.e., from the PEM to the GDL). Additionally, or alternatively, the concentration of the PFA in the electrocatalyst layer may be varied in the xy-direction (i.e., with respect to a surface of the electrocatalyst layer), for example, from an inlet of the fuel cell to the outlet of the fuel cell.
  • PFA may also be in a layer form, for example, as a layer between the electrocatalyst layer and the PEM or as a layer between the electrocatalyst layer and the GDL to enhance its hydrophobic properties.
  • PFA may be uniformly or non-uniformly distributed in the xy-direction.
  • the amount of PFA in the resulting electrode after polymerization may range from, for example, about 0.1 wt% of the total ionomer in the electrocatalyst layer to about 20 wt% of the total ionomer in the electrocatalyst layer, depending on its penetration into the ionomer of the electrocatalyst layer. For example, if PFA is dispersed within the electrocatalyst layer, then the amount of PFA in the resulting electrode after polymerization is preferably less than 8 wt% of the total ionomer in the electrocatalyst layer.
  • the amount of PFA in the resulting electrode after polymerization may be higher, for example, less than 20 wt% of the total ionomer in the electrocatalyst layer, thereby forming a gradient in hydrophobicity in the z-direction of the electrocatalyst layer.
  • the electrocatalyst composition typically comprises an electrocatalyst, such as a noble metal, for example, platinum, ruthenium, and iridium; a non-noble metal, for example, cobalt, nickel, iron, chromium, and tungsten; or combinations or alloys thereof.
  • the electrocatalyst is a platinum-cobalt alloy.
  • the electrocatalyst may be a non-noble metal, such as those described in published U.S. Appl. No. 2004/0096728.
  • the electrocatalyst may be supported on an electrically conductive material, such as a carbonaceous or graphitic support material, for example, a carbon black or carbide, or other oxidatively stable supports.
  • the electrocatalyst composition may optionally include a pore former, such as methyl cellulose, durene, camphene, camphor, and naphthalene, that is removed in the process of making the electrocatalyst layer to increase the porosity thereof.
  • the electrocatalyst composition may optionally contain an ionomer, such as, but not limited to, a perfluorinated ionomer, a partially fluorinated ionomer, or a non- fluorinated ionomer; and an optional solvent, for example, a polar aprotic solvent, such as N-methylpyrrolidinone, dimethylsulfoxide, and N,N-dimethylacetamide.
  • the electrocatalyst composition may optionally include other additives, such as carbonaceous particles and carbon nanotubes and/or nanofibres.
  • monomeric furfuryl alcohol is mixed with the electrocatalyst composition by any method known in the art, such as stirring, shear mixing, microfluidizing, and ultrasonic mixing.
  • the monomeric furfuryl alcohol may be employed in the form of a neat solution or dispersed in a solvent, such as isopropanol, ethanol, methanol, deionized water, or mixtures thereof, before adding to the electrocatalyst composition.
  • a solvent such as isopropanol, ethanol, methanol, deionized water, or mixtures thereof.
  • an acid catalyst may be added to the electrocatalyst composition to induce and/or enhance the polymerization process.
  • the electrocatalyst composition may be applied onto a sheet material by any method known in the art, such as knife-coating, slot-die coating, dip-coating, microgravure coating, spraying, and screen-printing.
  • the sheet material is the surface of the electrocatalyst layer.
  • the sheet material may be a transfer material such as polytetrafluoroethylene, polyester, and polyimide sheet materials that can be used to decal transfer the electrocatalyst layer to a surface of the GDL to form a gas diffusion electrode, or to a surface of the PEM to form a catalyst-coated membrane (CCM).
  • CCM catalyst-coated membrane
  • the electrocatalyst composition may be applied onto a surface of the sheet material to form an electrocatalyst layer, and then monomeric furfuryl alcohol is applied onto a surface of the electrocatalyst layer by any method known in the art, such as those described above.
  • monomeric furfuryl alcohol may also be applied to the surface of the sheet material before application of the electrocatalyst composition.
  • the monomeric furfuryl alcohol and electrocatalyst layer may be subjected to impregnation conditions prior to polymerization to create a non-uniform distribution of furfuryl alcohol in the electrocatalyst layer, for example, a gradient of furfuryl alcohol through the thickness of the electrocatalyst layer.
  • monomeric furfuryl alcohol may be homogeneously impregnated into the electrocatalyst layer by using a sufficient amount of monomeric furfuryl alcohol and/or subjecting the monomeric furfuryl alcohol and electrocatalyst layer to the appropriate impregnation conditions.
  • Impregnation of the monomeric furfuryl alcohol into the electrocatalyst layer may be controlled by varying the amount of furfuryl alcohol and/or the impregnation conditions, such as the impregnation temperature and time, to achieve the desired gradient through the thickness of the electrocatalyst layer.
  • Polymerization of the monomeric furfuryl alcohol may occur before and/or during bonding of the MEA.
  • the monomeric furfuryl alcohol may be polymerized during or after application to the sheet material, and before assembling the MEA.
  • polymerization occurs simultaneously with bonding of the MEA components by assembling an MEA with an electrocatalyst layer containing monomeric (unpolymerized) furfuryl alcohol and then subjecting the MEA to bonding conditions that are similar to the required polymerization conditions.
  • the monomeric furfuryl alcohol may be partially polymerized during or after application to the sheet material, and then further polymerized during MEA bonding.
  • the polymerization conditions may include a polymerization temperature, for example, heating to a temperature of between about 80°C and about 140°C, and a polymerization time of about 5 seconds to about 15 minutes.
  • the polymerization time will be dependent on the polymerization temperature and the amount of furfuryl alcohol. For instance, the polymerization time from about 5 to 10 minutes for a low polymerization temperature and a high amount of furfuryl alcohol, but may range from about 1 to 2 minutes for a high polymerization temperature and a low amount of furfuryl alcohol.
  • the furfuryl alcohol may be cross-linked by exposure to ultraviolet rays, for example, by exposure to a mercury lamp.
  • the amount of furfuryl alcohol and/or degree of polymerization of the furfuryl alcohol in or on the electrocatalyst layer is non-uniform in the xy-direction to preferentially control the hydrophobic properties in different regions of the fuel cell.
  • a higher concentration of monomeric furfuryl alcohol and/or a greater degree of polymerization of the monomeric furfuryl alcohol may be employed in regions of the electrocatalyst layer that tends to be wetter during fuel cell operation (for example, the outlet region of the fuel cell in comparison to the inlet region) to improve water removal therefrom.
  • the loading of the electrocatalyst composition with monomeric furfuryl alcohol may be varied when it is applied to the sheet material.
  • the loading of monomeric furfuryl alcohol may be varied when it is applied to the electrocatalyst layer.
  • the polymerization conditions may be varied along the xy-direction of the electrocatalyst layer to vary the degree of polymerization.
  • an ionomer layer may also be employed between the PEM and electrocatalyst layer and/or between the electrocatalyst layer and GDL.
  • the ionomer layer may also contain monomeric furfuryl alcohol and then polymerized after application to a surface of the PEM and/or the electrocatalyst layer, for example, polymerizing immediately after application or polymerizing during MEA bonding.
  • the ionomer layer may be applied by any method known in the art, such as those described above, and may be uniform or non-uniform with respect to the planar surface of the catalyst layer.
  • An electrocatalyst composition is made by mixing 662 grams of 10% by weight Nafion ® solution with 132 grams of a platinum-containing catalyst powder, 2 grams of monomeric furfuryl alcohol, 6 grams of isopropanol, and 290 grams of de- ionized water. The mixture is then mixed using an ultrasonic mixer and then sprayed onto a fluid diffusion layer comprising a carbon fiber paper and a microporous carbonaceous layer. The resulting electrode is then subjected to a temperature of about 140°C for about 2 to 10 minutes to polymerize the monomeric furfuryl alcohol, thereby producing an electrode with PFA.
  • a solution of monomeric furfuryl alcohol is prepared by mixing 6 grams of monomeric furfuryl alcohol with 12 grams of isopropanol and 6 grams of de-ionized water. The solution is then sprayed onto the cathode electrocatalyst layer of a CCM. The monomeric furfuryl alcohol is allowed to penetrate into the cathode electrocatalyst layer for about 1 hour at 20 0 C. After penetration, the CCM is heated to about 140 0 C for about 2 to about 10 minutes to polymerize the monomeric furfuryl alcohol, thereby producing a CCM with PFA in the cathode electrocatalyst layer.
  • a solution of monomeric furfuryl alcohol was prepared by mixing 6 grams of monomeric furfuryl alcohol (98% Lancaster) with 12 grams of isopropanol and 6 grams of de-ionized water. The solution was then sprayed at room temperature onto a GDL having a sublayer containing carbon black and Nafion ® on one surface of the substrate. The sprayed GDL was then placed onto a hot plate at 140 0 C for about 10 minutes to polymerize the furfuryl alcohol. The final loading of PFA was about 45wt%.
  • the polymerized GDL was then subjected to a mercury intrusion porosimetry test using the Autopore III supplied by Micromeritics Instrument Corporation, and a series of through-plane permeability tests using the 58-21 Roughness and Air Permeance Tester supplied by Testing Machines (TMI Inc.). (A through-hole was bored through the bottom jig of the tester and a rubber seal was placed around the test piece so that air was forced from the top jig to the bottom jig through the test piece.)

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inert Electrodes (AREA)

Abstract

L'invention concerne une pile à combustible électrochimique comprenant un ensemble électrode à membrane constitué d'une anode possédant une couche de diffusion du gaz et une couche d'électrocatalyseur; d'une cathode possédant une couche de diffusion du gaz et une couche d'électrocatalyseur et d'une membrane échangeuse de protons placée entre l'anode et la cathode. Au moins l'une ou l'autre des couches d'électrocatalyseur anodique et cathodique comprennent un électrocatalyseur et un alcool de polyfurfuryle. L'alcool de polyfurfuryle peut être réparti uniformément ou non uniformément à l'intérieur de la couche d'électrocatalyseur. L'invention concerne également des procédés de fabrication de la couche d'électrocatalyseur possédant un électrocatalyseur et un alcool de polyfurfuryle.
PCT/US2007/083954 2006-11-08 2007-11-07 Couches d'électrocatalyseurs pour piles à combustible et leurs procédés de fabrication WO2008058199A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA002668895A CA2668895A1 (fr) 2006-11-08 2007-11-07 Couches d'electrocatalyseurs pour piles a combustible et leurs procedes de fabrication

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US86487706P 2006-11-08 2006-11-08
US60/864,877 2006-11-08

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111540882A (zh) * 2020-06-04 2020-08-14 湖北亿纬动力有限公司 一种负极极片、其制备方法和用途
CN114566653A (zh) * 2021-09-08 2022-05-31 中自环保科技股份有限公司 一种非均匀催化剂层、膜电极及其制备方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109585858B (zh) * 2018-10-08 2021-06-15 武汉船用电力推进装置研究所（中国船舶重工集团公司第七一二研究所） 一种具有疏水性的燃料电池气体扩散层的制备方法

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US5500292A (en) * 1992-03-09 1996-03-19 Hitachi, Ltd. Polymer electrolyte hydrogen-oxygen fuel cell where the polymer electrolyte has a water repellency gradient and a catalytically active component concentration gradiem across oxygen electrode
EP1217680A2 (fr) * 1994-12-07 2002-06-26 Japan Gore-Tex, Inc. Ensemble membrane échange d'ions-électrode pour cellule électrochimique
JPH09283153A (ja) * 1996-04-09 1997-10-31 Ishikawajima Harima Heavy Ind Co Ltd 固体高分子電解質型燃料電池
US6087032A (en) * 1998-08-13 2000-07-11 Asahi Glass Company Ltd. Solid polymer electrolyte type fuel cell
US6300000B1 (en) * 1999-06-18 2001-10-09 Gore Enterprise Holdings Fuel cell membrane electrode assemblies with improved power outputs and poison resistance
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US20060024562A1 (en) * 2003-11-26 2006-02-02 Hitachi Maxell, Ltd. Power generating element for liquid fuel cell, method for producing the same, and liquid fuel cell using the same

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111540882A (zh) * 2020-06-04 2020-08-14 湖北亿纬动力有限公司 一种负极极片、其制备方法和用途
CN114566653A (zh) * 2021-09-08 2022-05-31 中自环保科技股份有限公司 一种非均匀催化剂层、膜电极及其制备方法
CN114566653B (zh) * 2021-09-08 2023-01-31 中自环保科技股份有限公司 一种非均匀催化剂层、膜电极及其制备方法

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CN101558519A (zh) 2009-10-14
KR20090082457A (ko) 2009-07-30
CA2668895A1 (fr) 2008-05-15

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