Composition for manufacturing electrode of membrane-electrode assembly for fuel cells and method for manufacturing electrode of membrane-electrode assembly for fuel cells using the same

Abstract

Described herein is a composition for manufacturing an electrode of a membrane-electrode assembly for fuel cells and a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells including the same. More particularly, described herein is a composition for manufacturing an electrode of a membrane-electrode assembly for fuel cells which can improve porosity in the electrode and thereby mass transport capability of reactive gases by mixing a second carbon having lower crystallinity than a first carbon to produce an electrode and applying a voltage to the electrode to remove only the second carbon, and a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells including the same.

Claims

1. A method for manufacturing an electrode of a membrane-electrode assembly for fuel cells comprising: coating a catalyst composite comprising a first carbon and a catalyst metal supported on the first carbon with an ionomer binder; mixing the ionomer binder-coated catalyst composite with a second carbon and a solvent to prepare a catalyst ink; producing an electrode using the catalyst ink; and applying a voltage to the electrode to remove the second carbon, wherein the second carbon has a lower crystallinity than the first carbon, and wherein the removal of the second carbon is carried out at a relative humidity (RH) of 70% or more.

2. The method according to claim 1, wherein the first carbon comprises at least one selected from the group consisting of carbon black, carbon nanotube, carbon nanofiber, carbon nanowire, carbon nanohorn or graphene.

3. The method according to claim 1, wherein the catalyst metal comprises at least one selected from the group consisting of platinum (Pt), palladium (Pd), ruthenium (Ru), iridium (Ir), gold (Au), silver (Ag), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), molybdenum (Mo) or yttrium (Y).

4. The method according to claim 1, wherein the coating of the ionomer binder comprises: preparing a mixture consisting of the catalyst composite, an ionomer binder and a solvent; and drying and heat-treating the mixture.

5. The method according to claim 4, wherein the heat-treatment is carried out at a temperature from an alpha transition temperature of the ionomer binder to an alpha transition temperature+100 C. for 10 minutes to 10 hours.

6. The method according to claim 1, wherein the second carbon comprises at least one selected from the group consisting of carbon black, carbon nanotube, carbon nanofiber, carbon nanowire or carbon nanohorn.

7. The method according to claim 1, wherein the second carbon has an at least 10% lower degree of crystallinity than the first carbon.

8. The method according to claim 1, wherein the solvent is at least one alcohol selected from the group consisting of isopropyl alcohol, normal propyl alcohol or ethyl alcohol, deionized water, or a mixture thereof.

9. The method according to claim 1, wherein the catalyst ink comprises 10 to 50% by weight of the ionomer binder and 0.1 to 50% by weight of the second carbon, based on the total weight (%) of the catalyst composite, the ionomer binder and the second carbon.

10. The method according to claim 1, wherein the removal of the second carbon is carried out by applying a voltage of 1.0V to 1.6V to the electrode for 5 seconds to 2 minutes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

(2) FIG. 1 is a flowchart illustrating a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells according to the present disclosure;

(3) FIG. 2A is a sectional view illustrating a membrane-electrode assembly including the electrode of a membrane-electrode assembly for fuel cells before removal of second carbon in the electrode; and

(4) FIG. 2B is a sectional view illustrating a membrane-electrode assembly including the electrode of a membrane-electrode assembly for fuel cells, showing formation of sufficient pores after removal of second carbon in the electrode.

(5) The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

(6) The present disclosure will be understood with reference to the annexed drawings. However, the present disclosure is not limited strictly to the forms disclosed herein.

(7) Like reference numbers refer to like elements throughout the description of the figures. In the drawings, the sizes of structures are exaggerated for clarity. It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms and are used only to distinguish one element from another. For example, within the scope defined by the present disclosure, a first element may be referred to as a second element and similarly, a second element may be referred to as a first element. Singular forms are intended to include plural forms as well unless context clearly indicates otherwise.

(8) It will be further understood that the terms comprises, has and the like, when used in this specification, specify the presence of stated features, number, steps, operations, elements, components or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof. In addition, it will be understood that, when an element such as a layer, film, region or substrate is referred to as being on another element, it can be directly on the other element or an intervening element may also be present. It will also be understood that, when an element such as a layer, film, region or substrate is referred to as being under another element, it can be directly under the other element or an intervening element may also be present.

(9) Unless context clearly indicates otherwise, all numbers, figures and/or expressions that represent ingredients, reaction conditions, polymer compositions and amounts of mixtures used in the specification are approximations that reflect various uncertainties of measurement occurring inherently in obtaining these figures among other things. For this reason, it should be understood that, in all cases, the term about modifies all the numbers, figures and/or expressions. In addition, when numerical ranges are disclosed in the description, these numerical ranges are continuous and include all numbers from the minimum to the maximum including the maximum within the ranges unless otherwise defined. Furthermore, when the range is referred to as an integer, it includes all integers from the minimum to the maximum including the maximum within the range, unless otherwise defined.

(10) It should be understood that, in the specification, when the range is referred to regarding a parameter, the parameter encompasses all figures including end points disclosed within the range. For example, the range of 5 to 10 includes figures of 5, 6, 7, 8, 9, and 10, as well as arbitrary sub-ranges such as ranges of 6 to 10, 7 to 10, 6 to 9, and 7 to 9, and any figures, such as 5.5, 6.5, 7.5, 5.5 to 8.5 and 6.5 to 9, between appropriate integers that fall within the range. In addition, for example, the range of 10% to 30% encompasses all integers that include figures such as 10%, 11%, 12% and 13%, as well as 30%, and any sub-ranges of 10% to 15%, 12% to 18%, or 20% to 30%, as well as any figures, such as 10.5%, 15.5% and 25.5%, between appropriate integers that fall within the range.

(11) The present disclosure relates to a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells, which can improve porosity in the electrode by a simple process including mixing a second carbon having lower crystallinity than a catalyst metal-supported first carbon to produce an electrode and applying a voltage to the electrode to remove only second carbon by carbon corrosion. In addition, the method has advantages of improving the porosity of the electrode and thus enhancing mass transport capability of reactive gases.

(12) FIG. 1 is a flowchart illustrating a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells according to the present disclosure. Referring to this drawing, the manufacturing method of an electrode for a membrane-electrode assembly may include coating a catalyst composite with an ionomer binder (S100), preparing a catalyst ink (S200), producing an electrode (S300) and applying a voltage to the electrode (S400).

(13) More specifically, the present disclosure relates to a method for manufacturing an electrode of a membrane-electrode assembly for fuel cells, which includes: coating a catalyst composite including a first carbon and a catalyst metal supported on the first carbon with an ionomer binder; mixing the ionomer binder-coated catalyst composite with a second carbon and a solvent to prepare a catalyst ink; producing an electrode using the catalyst ink; and applying a voltage to the electrode to remove the second carbon.

(14) Hereinafter, respective steps to manufacture the electrode of a membrane-electrode assembly for fuel cells according to the present disclosure will be described in more detail with reference to FIG. 1.

(15) 1) Coating Ionomer Binder (S100)

(16) The step of coating an ionomer binder (S100) may include coating a catalyst composite including a first carbon and a catalyst metal supported on the first carbon with an ionomer binder. More specifically, the coating ionomer binder may include preparing a mixture consisting of the catalyst composite, an ionomer binder and a solvent, and drying and heat-treating the mixture.

(17) The first carbon used in the present disclosure may include one or more selected from the group consisting of carbon black, carbon nanotube, carbon nanofiber, carbon nanowire, carbon nanohorn and graphene, and functions to support the catalyst metal. In addition, the catalyst metal may include one or more selected from the group consisting of platinum (Pt), palladium (Pd), ruthenium (Ru), iridium (Ir), gold (Au), silver (Ag), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), molybdenum (Mo) and yttrium (Y).

(18) In the step of the preparing a mixture, the mixture can be prepared by adding the catalyst composite and the ionomer binder to the solvent, thoroughly stirring the resulting mixture at room temperature with a stirrer and subjecting the reaction solution to ultrasonication.

(19) The solvent may be at least one alcohol selected from the group consisting of isopropyl alcohol, normal propyl alcohol and ethyl alcohol; deionized water; or a mixture thereof.

(20) In the step of drying and heat-treating the mixture, the mixture may be dried to remove the solvent, and the residue (including obtained catalyst composite and ionomer binder) in the form of a cake may be heat-treated in a dryer to coat the entire surface of the catalyst composite with the ionomer binder.

(21) The heat-treatment may be carried out at a temperature from an alpha transition temperature of the ionomer binder to an alpha transition temperature+100 C. for 10 minutes to 10 hours. The alpha transition temperature (T) means a temperature at which crystallinity of a polymer rapidly changes. The alpha transition temperature may vary depending on the structure and kind of the ionomer. When the temperature of the heat-treatment is lower than the alpha transition temperature of the ionomer binder, the catalyst composite and the ionomer binder may be separated from each other upon re-dispersion in a solvent due to weak binding force therebetween. On the other hand, when the heat-treatment temperature is higher than the alpha transition temperature+100 C., thermal degradation of the ionomer binder is accelerated, or the ionomer binder may not be redispersed in the solvent due to excessive increase in degree of crystallinity of the ionomer binder and thus decreased solubility. In addition, when manufacturing a membrane-electrode assembly, an interfacial adhesion of the electrolyte membrane may be decreased. The heat-treatment temperature may range from the alpha transition temperature of the ionomer binder to the alpha transition temperature+50 C.

(22) In addition, the heat-treatment may be carried out for 10 minutes to 10 hours. When the heat-treatment time is shorter than 10 minutes, heat-treatment effects may be insufficient, and when the heat-treatment time is longer than 10 hours, thermal degradation of the ionomer binder may be accelerated, crystallinity is excessively increased or process cycle time is increased. Heat treatment of the mixture may be carried out for 30 minutes to 5 hours.

(23) The ionomer binder may be a perfluorinated sulfonic acid ionomer (PFSA), a hydrocarbon ionomer or a mixture thereof, such as a perfluorinated sulfonic acid ionomer.

(24) The perfluorinated sulfonic acid ionomer (PFSA) or hydrocarbon ionomer may have an alpha transition temperature of 60 to 130 C. The range of the alpha transition temperature may vary depending on the type and structure of the ionomer and the present disclosure is not limited thereto.

(25) 2) Preparing Catalyst Ink (S200)

(26) The step of preparing a catalyst ink (S200) may include mixing the ionomer binder-coated catalyst composite with a second carbon and a solvent to prepare a catalyst ink. At this time, the second carbon may include one or more selected from the group consisting of carbon black, carbon nanotube, carbon nanofiber, carbon nanowire and carbon nanohorn.

(27) The second carbon may have an at least 10% lower degree of crystallinity than the first carbon. Here, the degree of crystallinity means a weight proportion of a crystalline part with respect to the total content including the crystalline part and an amorphous part.

(28) The second carbon used should have an at least 10% lower degree of crystallinity than the first carbon in order to effectively remove the second carbon in the following step of applying a voltage to the electrode (S400). Specifically, when the degree of crystallinity of the second carbon is the same or 10% lower than that of the first carbon, the second carbon, which may form pores in the electrode, and the first carbon, which is a support of the catalyst metal, can be simultaneously removed by corrosion in the applying a voltage to the electrode (S400). For this reason, the catalyst metal may be detached from the first carbon and lost, or catalyst metal particles agglomerate together, resulting in deterioration of catalyst performance and thus performance of fuel cells. The second carbon may have an at least 20% lower degree of crystallinity than the first carbon. As a result, the first carbon may have a higher crystallinity than the second carbon. Conversely, the second carbon may have a lower crystallinity than the first carbon.

(29) The solvent may be at least one alcohol selected from the group consisting of isopropyl alcohol, normal propyl alcohol and ethyl alcohol, deionized water, or a mixture thereof.

(30) The catalyst ink may include 10 to 50% by weight of the ionomer binder and 0.1 to 50% by weight of the second carbon, based on the total weight (%) of the catalyst composite, the ionomer binder and the second carbon.

(31) The ionomer binder may be used in an amount of 10 to 50% by weight. When the content of the ionomer binder is less than 10% by weight, the catalyst composite may not be sufficiently connected or bound into a three dimensional network structure. On the other hand, when the content is higher than 50% by weight, excess ionomer binder may clog pores in the electrode, thus flooding the electrode. In one aspect, the ionomer binder may be used in an amount of 20 to 35% by weight.

(32) The second carbon may be present in an amount of 0.1 to 50% by weight, because, when the content of the second carbon is less than 0.1% by weight, fewer pores are formed in the electrode, making improvement in mass transport capability insufficient. When the content is higher than 50% by weight, excessive pores are formed in the electrode, potentially causing structural collapse of the electrode. The second carbon may be present in an amount of 0.5 to 20% by weight.

(33) 3) Producing Electrode (S300)

(34) The step of producing an electrode (S300) may include producing an electrode using the catalyst ink. The method of producing the electrode in step (S300) may be one of a variety of methods such as a decal transfer process, a spray process, an inkjet-printing process and the like.

(35) In one aspect of the present disclosure, the decal transfer process can be carried out by the following method. A decal transfer film may be coated with the catalyst ink using a bar coater and sufficiently dried to produce a decal electrode. Regarding the produced decal electrode, by controlling the content of catalyst ink and coating thickness, loading of platinum catalyst can be controlled.

(36) In addition, the decal transfer film may be a heat-resistant polymer, since the decal transfer film should be readily separated and able to endure high temperature heat-treatment conditions, when transferring the decal electrode coated on the decal transfer film to the electrolyte membrane. The heat-resistant polymer may include one or more selected from the group consisting of polytetrafluoroethylene (PTFE), poly(ethylene terephthalate) (PET), poly(butylene terephthalate) (PBT), poly(trimethylene terephthalate)) (PTT), poly(ethylene naphthalate) (PEN) and polyimide (PI). The decal electrode may be hot-pressed with the electrolyte membrane and the decal transfer film may then be removed to manufacture a membrane-electrode assembly.

(37) 4) Applying Voltage to the Electrode (S400)

(38) The step of applying a voltage to the electrode (S400) may include applying the voltage to the electrode to remove the second carbon. At this time, a part or the entirety of the second carbon may be removed from the electrode. Application of the voltage to the electrode (S400) may be carried out at a relative humidity of 70% or more. That is, humid gas may be sufficiently supplied to the electrode. When applying a voltage to the electrode while sufficiently supplying the humid gas thereto, electrochemical carbon corrosion occurs, as shown in the following Reaction Schemes 3 and 4, and at the same time, only low crystalline second carbon contained in the electrode can be selectively removed by oxidation.
[Reaction Scheme 3]
C+2H.sub.2O.fwdarw.CO.sub.2+4H.sup.+4e.sup.,E=0.207 V (vs. SHE)[3]
[Reaction Scheme 4]
C+H.sub.2O.fwdarw.CO+2H.sup.+2e.sup.,E=0.518 V (vs. SHE)[4]

(39) When the relative humidity is less than 70%, a sufficient amount of moisture for carbon corrosion is not present in the electrode and carbon corrosion of the second carbon does not sufficiently occur, making formation of pores in the electrode incomplete.

(40) In addition, application of the voltage to the electrode (S400) may be carried out by applying a voltage of 1.0V to 1.6V to the electrode for 5 seconds to 2 minutes. The voltage applied to the electrode may be 1.0V to 1.6V because, when the voltage is less than 1.0V, carbon corrosion of the second carbon, which is low-crystalline carbon for production of pores, may not sufficiently occur. On the other hand, when the voltage is higher than 1.6V, in addition to the second carbon, the first carbon, which is used as a support of the catalyst metal, may be corroded and removed as well. The voltage may be applied within the range of 1.1V to 1.4V.

(41) Regarding applying a voltage to the electrode (S400), voltage application time as well as the voltage range is important. The voltage application time may be between 5 seconds and 2 minutes. When the voltage application time is shorter than 5 seconds, carbon corrosion of the second carbon, which is low-crystalline carbon for production of pores, may not sufficiently occur, and when the voltage application time is longer than 2 minutes, in addition to the second carbon, the first carbon, which is used as a support of the catalyst metal, may be corroded and removed as well. In one aspect, the voltage application time may be 10 seconds to 30 seconds.

(42) FIG. 2A is a sectional view illustrating a membrane-electrode assembly including the electrode of a membrane-electrode assembly for fuel cells before removal of second carbon in the electrode. As shown in FIG. 2A, the cross-section of the membrane-electrode assembly has a structure in which a gas diffusion layer 30 is formed on an upper surface of an electrode 10 and an electrolyte membrane 20 is formed on a lower surface of the electrode 10. A catalyst metal 11 is supported on a first carbon 12 inside the electrode 10. In addition, the entire surface of the first carbon 12 and the catalyst metal 11 supported on the first carbon is coated with an ionomer binder 13 and a second carbon 14 is mixed with the resulting structure.

(43) FIG. 2B is a sectional view illustrating a membrane-electrode assembly including the electrode of a membrane-electrode assembly for fuel cells, showing formation of sufficient pores after removal of second carbon from the electrode. As shown in FIG. 2B, the second carbon 14 present in the electrode 10 of FIG. 2A is removed by electrochemical carbon corrosion and, at the same time, pores are sufficiently formed, and reactive gases and produced water can effectively move in the electrode of the membrane-electrode assembly.

(44) The electrode for a membrane-electrode assembly for fuel cells manufactured according to the present disclosure can improve porosity in the electrode and enhance mass transport capability of reactive gases by mixing a second carbon having lower crystallinity than a catalyst composite including a catalyst metal-supported first carbon to produce an electrode and applying a voltage to the electrode to selectively remove only second carbon by carbon corrosion.

(45) The electrode for a membrane-electrode assembly for fuel cells manufactured according to the present disclosure can improve performance of fuel cells by enhancing mass transport capability and improve operation stability under various operating conditions.

(46) The electrode for a membrane-electrode assembly for fuel cells manufactured according to the present disclosure can improve porosity of the electrode in a relatively simple and cost-efficient manner and thus reduce costs and improve product value.

(47) The effects of the present disclosure are not limited to those described above. The effects of the present disclosure will be clearly understood from the aforementioned description.

(48) It will be appreciated by those skilled in the art that changes may be made without departing from the principles and spirit of the present disclosure, the scope of which is defined in the appended claims and their equivalents.