CATALYST FOR FUEL CELL, METHOD FOR MANUFACTURING SAME, AND MEMBRANEELECTRODE ASSEMBLY COMPRISING SAME
20220263099 · 2022-08-18
Inventors
Cpc classification
Y02P70/50
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
Y02E60/50
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
International classification
Abstract
Disclosed are a catalyst for a fuel cell having excellent performance and durability, a method for manufacturing same, and a membrane-electrode assembly comprising same. The catalyst for a fuel cell of the present invention comprises: a support; and PtCo alloy particles supported on the support, wherein the PtCo alloy particles comprise a transition metal-doped or transition metal-partially alloyed surface that is modified with at least one transition metal selected from the group consisting of V, Cr, Mn, Fe, Ni, Cu, W, and Mo, or a transition metal-doped or transition metal-partially alloyed internal region including the transition metal.
Claims
1. A catalyst for a fuel cell comprising: a support; and a PtCo alloy particle supported on the support, wherein the PtCo alloy particle comprises a transition metal-doped or transition metal-partially alloyed surface modified with at least one transition metal selected from the group consisting of V, Cr, Mn, Fe, Ni, Cu, W, and Mo, or a transition metal-doped or transition metal-partially alloyed internal region including the transition metal.
2. The catalyst according to claim 1, wherein the PtCo alloy particle further comprises a transition metal-free surface or a transition metal-free internal region, where the transition metal does not exist.
3. The catalyst according to claim 2, wherein the PtCo alloy particle comprises the transition metal-doped or transition metal-partially alloyed internal region and the transition metal-free internal region, and wherein the transition metal-free internal region is farther away from an exposed surface of the PtCo alloy particle than the transition metal-doped or transition metal-partially alloyed internal region.
4. The catalyst according to claim 1, wherein, in the PtCo alloy particle, a molar ratio of Co to Pt is 0.05 to 0.4, and a molar ratio of the transition metal to Pt is 0.03 to 0.15.
5. The catalyst according to claim 1, wherein the transition metal is Cu.
6. A method for preparing a catalyst for a fuel cell, the method comprising: preparing a first catalyst comprising a support and a PtCo alloy particle supported on the support; mixing the first catalyst with a precursor of at least one transition metal selected from the group consisting of V, Cr, Mn, Fe, Ni, Cu, W, and Mo to obtain a mixture; and heat-treating the mixture.
7. The method according to claim 6, wherein a molar ratio of Co to Pt in the PtCo alloy particle of the first catalyst is 0.05 to 0.4.
8. The method according to claim 6, wherein the transition metal is Cu, and the precursor is CuCl.sub.2, CuSO.sub.4, CuO, Cu(CO.sub.2CH.sub.3).sub.2, CuS, Cu(NO.sub.3).sub.2, Cu(ClO.sub.4).sub.2, CuCO.sub.3, or a mixture of two or more thereof.
9. The method according to claim 6, wherein the mixture is obtained by (i) dispersing the first catalyst in a solution or dispersion containing the precursor, (ii) mixing the solution or dispersion containing the precursor with a dispersion containing the first catalyst, or (iii) directly mixing the precursor in a solid phase with the first catalyst in a solid phase.
10. The method according to claim 6, wherein the mixture is obtained by (i) dispersing the first catalyst in a solution or dispersion containing the precursor, or (ii) mixing the solution or dispersion containing the precursor with a dispersion containing the first catalyst, and the method further comprises drying the mixture before the heat-treating.
11. The method according to claim 6, wherein the heat-treating is performed at 100 to 300° C. in an atmosphere of a reductive gas or in an atmosphere of a mixed gas including the reductive gas and an inactive gas for 10 to 60 minutes.
12. The method according to claim 11, wherein the heat-treating is performed in an atmosphere of the reductive gas, and the reductive gas is NH.sub.3 gas.
13. The method according to claim 11, wherein the heat-treating is performed in the atmosphere of the mixed gas, and the mixed gas comprises 5 to 15 vol % of the reductive gas.
14. The method according to claim 11, wherein the heat-treating is performed in the atmosphere of the mixed gas, and the mixed gas comprises H.sub.2 gas as the reductive gas and N.sub.2 or Ar gas as the inactive gas.
15. The method according to claim 11, wherein the heat-treating is performed in the atmosphere of the mixed gas, and the mixed gas comprises NH.sub.3 gas as the reductive gas and N.sub.2 or Ar gas as the inactive gas.
16. A membrane-electrode assembly comprising: an anode; a cathode; and a polymer electrolyte membrane interposed between the anode and the cathode, wherein at least one of the anode and cathode comprises the catalyst according to claim 1.
Description
DESCRIPTION OF DRAWINGS
[0033] The accompanying drawings, which are provided for better understanding of the present disclosure and constitute a part of the present specification, are given to exemplify the embodiments of the present disclosure and describe the principles and features of the present disclosure with reference to the following detailed description, in which:
[0034]
[0035] (a) and (b) of
[0036] (a) and (b) of
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
BEST MODE
[0044] Hereinafter, the present disclosure will be described in more detail with reference to specific examples. However, the following examples are provided only for better understanding of the present disclosure, and should not be construed as limiting the scope of the present disclosure.
[0045]
[0046] As illustrated in
[0047] The support 11 may be (i) a carbon-based support, (ii) a porous inorganic oxide support such as zirconia, alumina, titania, silica, and ceria, or (iii) a zeolite support.
[0048] When the support 11 is a carbon-based support, the first catalyst 10 may be represented as a PtCo/C catalyst. The carbon-based support may be graphite, super P, carbon fiber, carbon sheet, carbon black, Ketjen black, Denka black, acetylene black, carbon nanotubes (CNT), carbon spheres, carbon ribbon, fullerene, active carbon, carbon nanowires, carbon nanoballs, carbon nanohorns, carbon nanocages, carbon nanorings, ordered nano-/meso-porous carbon, carbon aerogel, mesoporous carbon, graphene, stabilized carbon, or a combination of two or more thereof.
[0049] As illustrated in
[0050] According to the present disclosure, the first catalyst 10 is doped and/or partially alloyed with at least one transition metal selected from the group consisting of V, Cr, Mn, Fe, Ni, Cu, W, and Mo.
[0051] The doping and/or partially alloying process includes mixing the precursor of the transition metal with the first catalyst 10 to obtain a mixture and heat-treating the mixture.
[0052] For example, the transition metal may be Cu, and the precursor of the transition metal may be CuCl.sub.2, CuSO.sub.4, CuO, Cu(CO.sub.2CH.sub.3).sub.2, CuS, Cu(NO.sub.3).sub.2, Cu(ClO.sub.4).sub.2, CuCO.sub.3, or a mixture of two or more thereof.
[0053] The mixture may be obtained by (i) a first method of dispersing the first catalyst in a solution or dispersion containing the precursor, (ii) a second method of mixing a solution or dispersion containing the precursor with a dispersion containing the first catalyst, or (iii) a third method of directly mixing the precursor in a solid phase with the first catalyst in a solid phase.
[0054] However, the liquid mixture obtained by the first or second method may be more homogeneous than the solid mixture obtained by the third method, and thus is more advantageous in doping and/or partially alloying the first catalyst uniformly.
[0055] When the mixture is obtained by the first or second method, the method may further include drying the mixture before the heat treatment.
[0056] The heat treatment of the mixture may be performed in an atmosphere of a reductive gas or in an atmosphere of a mixed gas containing an inactive gas and the reductive gas at 100 to 300° C. for 10 to 60 minutes. For example, the heat treatment of the mixture may be performed in a tube furnace.
[0057] When the heat treatment of the mixture is performed in the atmosphere of the reductive gas, the reductive gas may be NH.sub.3 gas.
[0058] When the heat treatment of the mixture is performed in the atmosphere of the mixed gas containing the inactive gas and the reductive gas, the inactive gas may be N.sub.2 or Ar gas, and the reductive gas may be H.sub.2 gas, NH.sub.3 gas, or a combination thereof. The mixed gas may contain 5 to 15 vol % of the reductive gas and 85 to 95 vol % of the inactive gas.
[0059] The heat treatment performed in the mixed gas atmosphere may be carried out by introducing the mixture into an electric furnace, elevating the temperature under an inactive gas (for example, N.sub.2 or Ar gas), and supplying a reductive gas (for example, NH.sub.3 gas) to the electric furnace when the temperature of the electric furnace reaches a target temperature.
[0060] The catalyst 100 of the present disclosure can be obtained by completing the doping and/or partial alloying of the PtCo catalyst 10 with the transition metal through the heat treatment of the mixture.
[0061] As illustrated in
[0062] The support 110 is the same as the support 11 of the first catalyst 10 used for the preparation of the catalyst 100. The support 110 may be (i) a carbon-based support, (ii) a porous inorganic oxide support such as zirconia, alumina, titania, silica, and ceria, or (iii) a zeolite support. The carbon-based support may be graphite, super P, carbon fiber, carbon sheet, carbon black, Ketjen black, Denka black, acetylene black, carbon nanotubes (CNT), carbon spheres, carbon ribbon, fullerene, active carbon, carbon nanowires, carbon nanoballs, carbon nanohorns, carbon nanocages, carbon nanorings, ordered nano-/meso-porous carbon, carbon aerogel, mesoporous carbon, graphene, stabilized carbon, or a combination of two or more thereof.
[0063] As illustrated in
[0064] Since the PtCo alloy particle 120 of the present disclosure is basically a binary alloy of Pt and Co, the PtCo alloy particle 120 further includes a transition metal-free surface and/or a transition metal-free internal region, where no transition metal exists. The transition metal-doped or transition metal-partially alloyed surface and the transition metal-doped or transition metal-partially alloyed internal region include a mixture of Pt, Co, and Cu, whereas the transition metal-free surface and the transition metal-free internal region include Pt and Co, but do not include Cu.
[0065] The PtCo alloy particle 120 of the present disclosure is different from a particle of ternary alloy in that it is basically a particle of binary alloy of Pt and Co which is only partially doped and/or partially alloyed with the transition metal (i.e., a particle including the transition metal-free surface and/or the transition metal-free internal region) while the particle of ternary alloy is a particle obtained by alloying the transition metal with Pt and Co (i.e., a particle throughout which the transition metal is uniformly distributed together with Pt and Co).
[0066] As illustrated in
[0067] When the PtCo alloy particle 120 has a second or third structure, the transition metal-free internal region may be farther away from an exposed surface of the PtCo alloy particle than the transition metal-doped or transition metal-partially alloyed internal region.
[0068] According to an embodiment of the present disclosure, a molar ratio of Co to Pt in the PtCo alloy particle 120 may be 0.05 to 0.4, and a molar ratio of the transition metal to Pt may be 0.03 to 0.15.
[0069] The catalyst 100 for a fuel cell of the present disclosure, prepared by doping and/or partially alloying the PtCo alloy particles 12 of the PtCo catalyst 10 with a transition metal (Me), is represented as a Me-PtCo catalyst, which is distinguished from the PtCoMe catalyst, which is a ternary alloy of Pt, Co and a transition metal (Me).
[0070] For example, the catalyst 100 of the present disclosure may be a Cu—PtCo catalyst containing a PtCo alloy particle 120 doped and/or partially alloyed with Cu, which is distinguished from the PtCoCu catalyst containing a particle formed of a ternary alloy of Pt, Co and Cu.
[0071] In addition, when the support 110 is a carbon-based support and the transition metal which is doped and/or partially alloyed in the PtCo alloy particle 120 is Cu, the catalyst 100 of the present disclosure is represented as a Cu—PtCo/C catalyst, which is distinguished from a PtCoCu/C catalyst in which a ternary alloy of Pt, Co, and Cu is dispersed in the form of particles on a carbon-based support.
[0072] The catalyst 100 of the present disclosure is dispersed in a dispersion medium along with an ionomer to obtain an electrode slurry, and an anode and a cathode are formed, respectively, on two surfaces of a polymer electrolyte membrane (PEM) using the electrode slurry through decal transfer or direct coating to manufacture the membrane-electrode assembly (MEA) of the present disclosure.
[0073] Alternatively, the membrane-electrode assembly (MEA) of the present disclosure includes an anode, a cathode, and a polymer electrolyte membrane (PEM) disposed therebetween, wherein one of the anode and cathode includes the catalyst 100 of the present disclosure and the other thereof includes a conventional platinum or platinum-based alloy catalyst (e.g., a Pt/C catalyst, PtCo/C catalyst, PtCoCu/C catalyst, PtCoNi/C catalyst, etc.), instead of the catalyst 100 of the present disclosure.
[0074] The ionomer dispersed in the dispersion medium along with the catalyst 100 serves to transfer cations, and also serves as a binder for improving adhesion between the catalyst 100 and the polymer electrolyte membrane (PEM).
[0075] The ionomer may have at least one ion-conducting group selected from the group consisting of a sulfonic acid group, a carboxyl group, a boronic acid group, a phosphoric acid group, an imide group, a sulfonimide group, a sulfonamide group, and a sulfonic fluoride group.
[0076] For example, the ionomer may be a fluorine-based ionomer such as poly(perfluorosulfonic acid) or poly(perfluorocarboxylic acid).
[0077] Alternatively, the ionomer may be a hydrocarbon-based polymer such as sulfonated polyimide (S-PI), sulfonated polyarylethersulfone (S-PAES), sulfonated polyetheretherketone (SPEEK), sulfonated polybenzimidazole (SPBI), sulfonated polysulfone (S-PSU), sulfonated polystyrene (S-PS), sulfonated polyphosphazene, sulfonated polyquinoxaline, sulfonated polyketone, sulfonated polyphenylene oxide, sulfonated polyether sulfone, sulfonated polyether ketone, sulfonated polyphenylene sulfone, sulfonated polyphenylene sulfide, sulfonated polyphenylene sulfide sulfone, sulfonated polyphenylene sulfide sulfone nitrile, sulfonated polyarylene ether, sulfonated polyarylene ether nitrile, sulfonated polyarylene ether ether nitrile, or sulfonated polyarylene ether sulfone ketone.
[0078] The dispersion medium of the electrode slurry in which the catalyst 100 and the electrode slurry are dispersed may be water, a hydrophilic solvent, an organic solvent, or a mixture of two or more thereof.
[0079] The hydrophilic solvent may be a compound containing, as a main chain, a linear or branched saturated or unsaturated hydrocarbon having 1 to 12 carbon atoms, and having at least one functional group selected from the group consisting of alcohols, isopropyl alcohol, ketones, aldehydes, carbonates, carboxylates, carboxylic acids, ethers and amides.
[0080] The organic solvent may be N-methylpyrrolidone (NMP), dimethylsulfoxide (DMSO), tetrahydrofuran (THF), dimethylacetamide (DMAc), or a mixture of two or more thereof, but is not limited thereto.
MODE FOR DISCLOSURE
[0081] Hereinafter, the present disclosure will be described in more detail with reference to specific examples. These examples are provided only for better understanding and should not be construed as limiting the scope of the present disclosure.
Example 1
[0082] 1 g of a PtCo/C catalyst (i.e., first catalyst) was dispersed in water to obtain a dispersion. In addition, 1.3 g of CuCl.sub.2 was dissolved in water to obtain a Cu precursor solution. The dispersion was mixed to homogeneity with the Cu precursor solution to obtain a mixed solution, and the mixed solution was dried to remove water to obtain a solid as a mixture of the PtCo/C catalyst and the Cu precursor. The solid was introduced into a tube furnace and heat-treated at 250° C. in a mixed gas atmosphere of H.sub.2 and N.sub.2 for 30 minutes to obtain a Cu—PtCo/C catalyst (hereinafter, referred to as a Cu—PtCo/C_H.sub.2 catalyst).
Example 2
[0083] A Cu—PtCo/C catalyst was obtained in the same manner as in Example 1, except that the heat treatment was performed in an NH.sub.3 gas atmosphere (hereinafter, the catalyst is referred to as Cu—PtCo/C_NH.sub.3 catalyst).
COMPARATIVE EXAMPLE 1
[0084] The same type of PtCo/C catalyst as the PtCo/C catalyst used as the first catalyst in Example 1 was prepared.
Comparative Example 2
[0085] The support was dispersed in water to obtain a dispersion. Subsequently, a Pt precursor (H.sub.2PtCl.sub.6), a Co precursor (CoCl.sub.2), and a Cu precursor (CuCl.sub.2) were mixed with the dispersion, and then a reduction reaction was performed by a polyol reduction method to obtain a PtCoCu/C catalyst as a ternary alloy catalyst.
[0086] [Transmission Electron Microscopy (TEM) Analysis of Catalyst]
[0087] (a) and (b) of
[0088] As can be seen from
[0089] As can be seen from the HR-TEM image of the Cu—PtCo/C_H.sub.2 catalyst [
[0090] [XRD Analysis of Catalyst]
[0091]
[0092] [CV Test, LSV Test, and Voltage Cycling Test]
[0093] A catalyst was dispersed in a mixture of isopropyl alcohol and water at a volume ratio of 7:3 through ultrasonic dispersion to prepare an electrode slurry. The electrode slurry was cast on a rotating disk electrode (RDE) and dried to produce an electrode. A cyclic voltammetry (CV) test (temperature: room temperature, electrolyte solution: 0.1M HClO.sub.4 aqueous solution saturated with N.sub.2) was performed on the electrode using an electrochemical measuring device to measure the electro-chemical surface area (ECSA) of the catalyst.
[0094]
[0095] Subsequently, the electrolyte solution was saturated with O.sub.2, and then a LSV (linear sweep voltammetry) test was performed to evaluate the oxidation reduction reaction (ORR) activity of the catalyst.
[0096]
[0097] In addition, in order to evaluate the electrochemical durability of the catalyst, a voltage cycling test (30,000 cycles) was performed at 0.6 to 1.0V on the electrolyte solution saturated with O.sub.2. The electro-chemical surface area (ECSA) was measured before and after the voltage cycling test and the ECSA loss was calculated based on the measured values, and the results are shown in Table 1 below.
TABLE-US-00001 TABLE 1 Com- Com- parative parative Example 1 Example 2 Example 1 Example 2 Catalyst Cu—PtCo/C_H.sub.2 Cu—PtCo/C_NH.sub.3 PtCo/C PtCoCu/C ECSA loss 28% 30% 36% 35%
[0098] As can be seen from Table 1 above, the catalysts of Examples, particularly the Cu—PtCo/C_H.sub.2 catalyst of Example 1, exhibited a notably lower ECSA loss than the catalysts of Comparative Examples, which means that the Cu—PtCo/C catalyst of the present disclosure, prepared by doping and/or partially alloying PtCo alloy particles with Cu, has higher durability than the PtCo/C catalyst of Comparative Example 1 as well as the PtCoCu/C catalyst of Comparative Example 2.
[0099] [MEA Performance Test]
[0100] A catalyst was dispersed in a mixture of isopropyl alcohol and water at a volume ratio of 7:3 through ultrasonic dispersion to prepare an electrode slurry. The electrode slurry was applied in an area of 25 cm.sup.2 to each of the first and second release films and dried in an oven at 90° C. for 8 hours to form a square anode and cathode, respectively. Subsequently, the first release film, the polymer electrolyte membrane, and the second release film were laminated and thermally compressed such that the anode and the cathode respectively contacted the first and second surfaces of a polymer-electrolyte membrane produced using perfluorosulfonic acid. Then, the first and second release films were removed to complete a membrane-electrode assembly. The membrane-electrode assembly was connected to a fuel cell unit cell test device and, after activation, the output performance was measured at 65° C. and normal pressure under high-humidity operating conditions (100% RH/100% RH) and low-humidity operating conditions (50% RH/50% RH).
[0101]