LAMINATED ELECTROLYTE MEMBRANE, MEMBRANE ELECTRODE ASSEMBLY, WATER ELECTROLYSIS CELL, STACK, AND WATER ELECTROLYSIS APPARATUS

Abstract

A laminated electrolyte membrane of an embodiment includes: a hydrocarbon-based electrolyte membrane; and a composite electrolyte membrane laminated with the hydrocarbon-based electrolyte, the composite electrolyte membrane containing a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less.

Claims

1. A laminated electrolyte membrane, comprising: a hydrocarbon-based electrolyte membrane; and a composite electrolyte membrane laminated with the hydrocarbon-based electrolyte, the composite electrolyte membrane containing a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less.

2. The membrane according to claim 1, wherein the superstrong acid metal oxide having the acid function (H0) of 12 or less in the composite electrolyte membrane is 20 mass % or more and 80 mass % or less.

3. The membrane according to claim 1, wherein, in the superstrong acid metal oxide, an oxide of an element Y containing at least one selected from the group consisting of: B, S, W, Mo, and V is supported on an oxide of an element X containing at least one selected from the group consisting of: Ti, Zr, Si, Sn, and Al.

4. The membrane according to claim 3, wherein the oxide of the element Y in the superstrong acid metal oxide is 2 mass % or more and 20 mass % or less.

5. The membrane according to claim 3, wherein the oxide of the element X is one or more oxides selected from the group consisting of: TiO.sub.2, SiO.sub.2, ZrO.sub.2, SnO.sub.2, SiAl.sub.xO.sub.y (0<x2, 2<y5), SiOAl.sub.2O.sub.3, and TiW.sub.O.sub. (0<1, 2<5), and the oxide of the element Y is one or more oxides selected from the group consisting of: SO.sub.4, BO.sub.3, WO.sub.3, VO.sub.V (12.5 or less), and MoO.sub.3.

6. The membrane according to claim 1, wherein the composite electrolyte membrane contains a radical scavenger or a hydrogen peroxide decomposer of 10 mass % or less.

7. The membrane according to claim 1, wherein the composite electrolyte membrane has a thickness of 10 m or more and 200 m or less.

8. The membrane according to claim 1, wherein the composite electrolyte membrane has a thickness of 11 m or more and 23 m or less.

9. The membrane according to claim 3, wherein the superstrong acid metal oxide is oxide particles, and the average primary particle diameter of the superstrong acid metal oxide is 1 nm or more and 1,000 nm or less.

10. The membrane according to claim 3, wherein the superstrong acid metal oxide is oxide particles, and the average primary particle diameter of the superstrong acid metal oxide is 4 nm or more and 200 nm or less.

11. The membrane according to claim 1, wherein the thickness of the laminated electrolyte membrane is 20 m or more and 400 m or less, and the thickness of the hydrocarbon-based electrolyte membrane is 10 m or more and 150 m or less.

12. The membrane according to claim 1, wherein the composite electrolyte membrane has a thickness of 10 m or more and 200 m or less.

13. A membrane electrode assembly comprising: a first electrode; a second electrode; and the laminated electrolyte membrane according to claim 1 between the first electrode and the second electrode.

14. A water electrolysis cell using the membrane electrode assembly according to claim 13.

15. A stack using the membrane electrode assembly according to claim 13.

16. A stack using the water electrolysis cell according to claim 14.

17. A water electrolysis apparatus using the membrane electrode assembly according to claim 13.

18. A water electrolysis apparatus using the water electrolysis cell according to claim 14.

19. A water electrolysis apparatus using the stack according to claim 15.

20. A water electrolysis apparatus using the stack according to claim 16.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a cross-sectional view of a laminated electrolyte membrane according to embodiments described herein;

[0009] FIG. 2 is a cross-sectional view of a laminated electrolyte membrane according to the embodiments;

[0010] FIG. 3 is a cross-sectional view of a membrane electrode assembly according to the embodiments;

[0011] FIGS. 4A, 4B, 4C, and 4D are low magnification transmission-type microphotographs of a catalyst cross section according to the embodiments;

[0012] FIG. 5 is a cross-sectional view of a water electrolysis cell according to the embodiments;

[0013] FIG. 6 is a cross-sectional view of a stack according to the embodiments; and

[0014] FIG. 7 is a schematic diagram of a water electrolysis apparatus according to the embodiments.

DETAILED DESCRIPTION

[0015] A laminated electrolyte membrane of an embodiment includes: a hydrocarbon-based electrolyte membrane; and a composite electrolyte membrane laminated with the hydrocarbon-based electrolyte, the composite electrolyte membrane containing a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less.

[0016] Hereinafter, embodiments will be described in detail with reference to the drawings. In the following description, same members are denoted by same reference signs, and description of such as members once described is omitted as appropriate.

First Embodiment

[0017] A laminated electrolyte membrane according to a first embodiment includes a hydrocarbon-based electrolyte membrane and a composite electrolyte membrane. The composite electrolyte membrane is laminated with the hydrocarbon-based electrolyte and contains a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less. When the laminated electrolyte membrane according to the embodiment is used as a water electrolysis electrolyte membrane, it is preferable in view of low membrane resistance of the electrolyte membrane, low crossover, and low resistance.

[0018] FIG. 1 is a cross-sectional view of a laminated electrolyte membrane 100 according to the first embodiment. The laminated electrolyte membrane 100 illustrated in FIG. 1 includes a hydrocarbon-based electrolyte membrane 1 and a composite electrolyte membrane 2. As in a laminated electrolyte membrane 101 illustrated in FIG. 2, the hydrocarbon-based electrolyte membrane 1 may be interposed between the composite electrolyte membranes 2. The laminated electrolyte membranes 100 and 101 may be laminated with the hydrocarbon-based electrolyte membrane 1 and the composite electrolyte membranes 2. It is preferable that the hydrocarbon-based electrolyte membrane 1 and the composite electrolyte membrane 2 have a laminated structure in direct contact. At least a part of a surface facing the composite electrolyte membrane 2 of the hydrocarbon-based electrolyte membrane 1 and at least a part of a surface facing the hydrocarbon-based electrolyte membrane 1 of the composite electrolyte membrane 2 are in direct contact. It is preferable that the whole surface of the surface facing the composite electrolyte membrane 2 of the hydrocarbon-based electrolyte membrane 1 and the whole surface facing the hydrocarbon-based electrolyte membrane 1 of the composite electrolyte membrane 2 are in direct contact with each other for the reason described in the embodiment.

[0019] The thickness of the laminated electrolyte membranes 100 and 101 is preferably 20 m or more and 400 m or less. It is not preferable that the thickness of the laminated electrolyte membranes 100 and 101 is less than 20 m, because the mechanical strength and durability are deteriorated due to the thin membrane. Further, it is not preferable that the thickness of the laminated electrolyte membranes 100 and 101 is thicker than 400 m, because membrane resistance becomes high, and the efficiency of water electrolysis is lowered. For the above-described reasons, the thickness of the laminated electrolyte membranes 100 and 101 is more preferably 30 m or more and 150 m or less, and even more preferably 35 m or more and 53 m or less.

[0020] In the hydrocarbon-based electrolyte membrane 1, gas permeability per unit membrane thickness is preferably smaller than nafion (trademark) of a fluorine-based electrolyte membrane. The hydrocarbon-based electrolyte membrane 1 is an electrolyte membrane using a hydrocarbon-based polymer electrolyte which does not contain fluorine as a main chain skeleton and has a heat-resistant main chain skeleton. The thickness of the hydrocarbon-based electrolyte membrane 1 is preferably 10 m or more and 150 m or less, and more preferably 13 m or more and 40 m or less.

[0021] The hydrocarbon-based polymer electrolyte is preferably a solid polymer electrolyte having a heat-resistant main chain skeleton. For the hydrocarbon-based polymer electrolyte, a polymer having a functional group such as a sulfonic acid group, a carboxylic acid group, a phosphonic acid group, a phosphinic acid group, a sulfonylimide group, and a phenolic hydroxyl group is used. Specific examples of the hydrocarbon-based polymer electrolyte include polyarylene-based, polyetheretherketone-based, polyether sulfone-based, polyphenylene sulfide-based, polyimide-based, and polybenzazole-based polymers in which main chain aromatic rings are sulfonated.

[0022] Furthermore, in order to increase the mechanical strength of these electrolyte membranes, the hydrocarbon-based electrolyte membrane 1 reinforced with a porous membrane may be used. Examples of specific porous membranes include, but are not limited to, polytetrafluoroethylene (PTFE), polyetheretherketone (PEEK), and polypropylene (PP). Further, a membrane to which additives are added can also be used to increase chemical durability. Examples of the additives include a radical scavenger and a radical decomposer. For example, an organic phosphorus compound, an aromatic amine-based compound, a phenol-based compound, a thioether-based compound, CeO.sub.2, and MnO.sub.2 can be used as additives. The radical scavenger or hydrogen peroxide decomposer is contained in the hydrocarbon-based electrolyte membrane 1 at a ratio of 0 mass % or more and 10 mass % or less.

[0023] The composite electrolyte membrane 2 is a membrane of a mixture containing a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (HO) of 12 or less. The composite electrolyte membrane 2 has excellent adhesiveness with the hydrocarbon-based electrolyte membrane 1 and imparts chemical resistance to an electrolyte membrane of a laminated electrolyte membrane. It is preferable that the superstrong acid metal oxide having an acid function (H0) of 12 or less in the composite electrolyte membrane is 20 mass % or more and 80 mass % or less. If the superstrong acid metal oxide is less than 20 mass %, the composite electrolyte membrane 2 laminated with the hydrocarbon-based electrolyte membrane 1 tends to peel off in water. Therefore, it becomes difficult to use as a water electrolysis electrolyte. It is not preferable that the hydrocarbon-based electrolyte membrane 1 and the composite electrolyte membrane 2 are peeled off in water, because an electrolysis voltage rises. On the other hand, it is not preferable that the superstrong acid metal oxide exceeds 80 mass %, because membrane resistance increases, and it becomes difficult to maintain a membrane structure. The thickness of the composite electrolyte membrane 2 is preferably 10 m or more and 200 m or less, and more preferably 11 m or more and 23 m or less.

[0024] In water electrolysis, hydrogen peroxide, hydroxy radicals and the like are generated during electrolysis, and a membrane is likely to be easily destructed chemically. Therefore, if the hydrocarbon-based electrolyte membrane 1 is used alone, there is a problem in durability. An electrolyte membrane using a perfluorosulfonic acid-based electrolyte is excellent in chemical resistance. However, when laminated with the hydrocarbon-based electrolyte membrane 1, the electrolyte membrane is easily peeled off in water. Therefore, although there is not much problem for use in a fuel cell, it cannot be used for a water electrolysis electrolyte membrane. The composite electrolyte membrane 2 containing a perfluorosulfonic acid based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less is excellent in chemical resistance and also excellent in adhesion to the hydrocarbon-based electrolyte membrane 1. Therefore, the laminated electrolyte membranes 100 and 101 according to the embodiment are suitable as a water electrolysis electrolyte membrane.

[0025] The superstrong acid metal oxide is oxide particles in which an oxide of an element Y containing at least one selected from the group consisting of B, S, W, Mo, and V is supported on an oxide of an element X containing at least one selected from the group consisting of Ti, Zr, Si, Sn, and Al. The primary particle diameter of the oxide particle is preferably 1 nm or more and 1,000 nm or less, and the average primary particle diameter of the oxide particle is more preferably 4 nm or more and 200 nm or less.

[0026] The oxide of the element Y supported on the oxide of the element X in the superstrong acid metal oxide is preferably 2 mass % or more and 20 mass % or less. It is not preferable that the supported amount is less than 2 mass % because proton conductivity is lowered. On the other hand, it is not preferable that the supported amount exceeds 20 mass % because the oxide component of the supported element Y tends to dissolve.

[0027] Specific examples of the oxides of the element X include, but are not limited to, at least one oxide selected from the group consisting of TiO.sub.2, SiO.sub.2, ZrO.sub.2, SnO.sub.2, SiAl.sub.xO.sub.y (0<x2, 2<y5), SiOAl.sub.2O.sub.3, and TiW.sub.O.sub. (0<1, 2<5).

[0028] Specific examples of the oxides of the element Y include, but are not limited to, at least one oxide selected from the group consisting of SO.sub.4, BO.sub.3, WO.sub.3, VO.sub.Y, (12.5), and MoO.sub.3.

[0029] Element distribution in the superstrong acid metal oxide is observed and analyzed by analyzing contained elements and contents by an inductively coupled plasma mass spectrometry (ICP-MS) and by mapping them by a scanning electron microscope/energy dispersive X-ray spectroscopy (SEM-EDX). In addition, it is preferable to use an X-ray diffractometer for specifying the oxide.

[0030] The radical scavenger or the hydrogen peroxide decomposer described in the hydrocarbon-based electrolyte membrane 1 is contained in the composite electrolyte membrane 2 at a ratio of 0 mass % or more and 10 mass % or less.

[0031] The perfluorosulfonic acid-based electrolyte is preferably a polymer having an acidic group such as sulfonic acid group or sulfonamide group in a fluorine-containing main chain skeleton. The perfluorosulfonic acid-based electrolyte imparts chemical resistance to the composite electrolyte membrane 2 and structural strength to the composite electrolyte membrane 2. Examples of the perfluorosulfonic acid based electrolyte include Nafion (TM, Du Pont), Aquivion (TM, SOLVAY), Flemion (TM, Asahi Kasei Corp.), and Aciplex (TM, Asahi Glass Co., Ltd.).

[0032] For preparing a composite membrane including a perfluorosulfonic acid based electrolyte and a superstrong acid metal oxide, a material obtained by dispersing a superstrong acid metal oxide in a perfluorosulfonic acid-based electrolyte dispersion solution is used. A solvent to be used for the dispersion may be any one as long as the perfluorosulfonic acid-based electrolyte and the superstrong acid metal oxide are dispersed in a solvent, and a concentration of the solvent may be any concentration as long as coating is possible. Examples of the solvent include, but are not limited to, water; alcohol solvents such as methanol, ethanol, isopropanol, 1-propanol and ethylene glycol; ether solvents such as tetrahydrofuran and dimethoxyethylene; and aprotic polar solvents such as N, N-dimethylformamide, and N-methylpyrrolidone. As a dispersion solvent, a mixed solvent of various solvents may be used.

[0033] As a method for dispersing the superstrong acid oxide in the perfluorosulfonic acid-based electrolyte dispersion solution, an existing method can be used. Examples of the methods include, but are not limited to, a pane shaker, a ball mill, and an ultrasonic dispersion device.

[0034] Next, the laminated electrolyte membrane 100 is prepared in which the composite electrolyte membrane 2 is formed on the hydrocarbon-based electrolyte membrane 1 by coating and drying the superstrong acid oxide on the hydrocarbon-based electrolyte membrane 1 by using the dispersed perfluorosulfonic acid electrolyte dispersion. Regarding a coating method, any method can be used as long as coating on an electrolyte membrane is possible, and examples of the method include, but are not limited to, a spin coating method, a blade coating method, an inkjet method, a gravure method, and a spray coating method.

[0035] The coated membrane is dried by heating drying, and a temperature thereof is preferably 60 C. or more and less than 250 C. A drying time can be adjusted according to a used solvent and the membrane thickness of an electrolyte. If the temperature is less than 60 C., the solvent is not sufficiently volatilized, and if the temperature is 250 C. or higher, the electrolyte membrane may be decomposed. In addition, to further improve adhesion of the membrane, it may be pressurized during heating drying. For example, preferably, in the case of hot pressing, a pressure is in the range where membrane deterioration does not occur, specifically, the pressure is preferably less than 50 kg/cm.sup.2. When the pressure is 50 kg/cm.sup.2 or more, a decrease in mechanical strength may occur. In addition, a roll method can be applied as a pressurized heating drying method.

Second Embodiment

[0036] A membrane electrode assembly (MEA) according to a second embodiment includes a first electrode, a second electrode, a hydrocarbon-based electrolyte membrane, and a composite electrolyte membrane. The composite electrolyte membrane is laminated with the hydrocarbon-based electrolyte and contains a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less. The membrane electrode assembly using a laminated electrolyte membrane according to the embodiment is preferable in that, when it is used for water electrolysis, membrane resistance of the electrolyte membrane is low, crossover is low, and resistance is low.

[0037] FIG. 3 is a cross-sectional view of a membrane electrode assembly 200 according to the second embodiment. A membrane electrode assembly 200 in FIG. 2 includes a first electrode 3, a second electrode 4, and a laminated electrolyte membrane 100. Instead of the laminated electrolyte membrane 100, a laminated electrolyte membrane 101 may be used.

[0038] The first electrode 3 is a cathode. The first electrode 3 includes a catalyst layer in contact with the laminated electrolyte membrane 100 and a support for supporting the catalyst layer. The second electrode 4 is an anode. The first electrode 3 includes a catalyst layer in contact with the laminated electrolyte membrane 100 and a support for supporting the catalyst layer.

[0039] The catalyst layer according to the embodiment is preferably a carrierless porous catalyst layer. To obtain high cell characteristics, a catalyst layer to be used generally includes a supported catalyst in which a catalyst is supported on a surface thereof by using a material such as carbon or a conductive oxide as a support. It has been reported that, although the material of the support hardly contributes to main electrocatalytic reaction, a catalyst material can be controlled for improvement of a reaction area of the catalyst material, and also a pore structure, electric conductivity, ion conductivity and the like can be improved by an electrochemical cell. Carrierless means that a carrier is not used for a catalyst included in a catalyst layer. This catalyst layer includes a catalyst unit having a porous structure or a laminated structure including a gap layer. In the case of using a noble metal catalyst, it is possible to maintain high characteristics and high durability of an electrochemical cell even when a small amount of a noble metal catalyst is used. FIGS. 4A and 4B illustrate a catalyst unit having a porous structure and a catalyst unit having a laminated structure including a gap layer, respectively. FIG. 4A illustrates a catalyst unit having a porous structure. FIG. 4B illustrates a catalyst unit having a laminated structure including a gap layer. In the case where a catalyst material is supported on a carrier, a catalyst is generally nano-sized particles. However, a catalyst in a catalyst unit having a porous structure is sponge-like. A catalyst in a catalyst unit having a laminated structure including a gap layer is nanosheet-like. By using a sponge-like or nanosheet-like catalyst, it is possible to improve characteristics of an electrochemical cell. An electrocatalytic reaction occurs on a catalyst surface, and therefore a catalyst shape affects atomic arrangement and electronic state of the catalyst surface. In a catalyst unit having a laminated structure including a gap layer, adjacent nanosheets are desirably partially integrated. Although a mechanism has not yet been elucidated completely, it is thought that proton conduction or hydrogen atom conduction for electrode reaction can be achieved more smoothly. Further, as indicated in FIG. 4C, higher properties can be obtained by making a nanosheet inside the laminated structure porous. This is because gas diffusion and water management can be improved. Durability and robustness can be further improved by disposing a porous nano-carbon layer (FIG. 4D) containing fibrous carbon or a nanoceramic material layer between the nanosheets inside the laminated structure. The catalyst contributing to main electrode reaction is hardly supported by fibrous carbon contained in the porous nano-carbon layer, and therefore a laminated structural unit including the porous nano-carbon layer is considered to be carrierless. Here, since the movement of substances such as discharge of moisture becomes smoother, a porosity of a catalyst layer is preferably 50 to 90 vol. %. In addition, if the porosity of the catalyst layer is within this range, the substances can be sufficiently moved without lowering the utilization efficiency of a noble metal.

[0040] The predetermined catalyst material used for the carrierless catalyst layer according to the embodiment contains at least one selected from the group consisting of noble metal elements such as Pt, Ru, Rh, Os, Ir, Pd, and Au. Such the catalyst material is excellent in catalytic activity, conductivity, and stability. The above-described metal may be used as an oxide and may be a composite oxide or mixed oxide containing two or more kinds of metals.

[0041] An optimum noble metal element can be appropriately selected in accordance with a reaction in which the MEA is used.

[0042] For example, when a hydrogen production reaction is needed as a water electrolysis cathode, a catalyst having a composition represented by Pt.sub.uM.sub.1-u is desirable. Here, u is 0<u1, and an element M is at least one selected from the group consisting of Co, Ni, Fe, Mn, Ta, W, Hf, Si, Mo, Ti, Zr, Nb, V, Cr, Al, and Sn. This catalyst contains Pt of more than 0 atomic % and 90 atomic % or less and the element M of 10 atomic % or more and less than 100 atomic %.

[0043] On the other hand, when an oxidation reaction of water (oxygen evolution reaction) is required as a water electrolysis anode, an oxide catalyst containing at least Ir, an oxide catalyst containing at least one of Pt, Ru, and Ir, a metal catalyst containing any one of Pt, Ru, and Ir, or an alloy catalyst containing any one of Pt, Ru, and Ir is desirable. The oxide catalyst is, for example, a catalyst having a composition represented by Ir.sub.zM.sub.1-xO. Here, z is 0.5<z, and the element M is at least selected from the group consisting of Co, Ni, Fe, Mn, Ta, W, Hf, Si, Mo, Ti, Zr, Nb, V, Cr, Sr, and Sn. This oxide catalyst contains the element M of 50 atomic % or more or 0 atomic % or more and less than 50 atomic % in the case of considering only a metal component element. Specific examples of an oxide catalyst include an oxide catalyst including metal of at least one selected from the group consisting of Pt, Ru, and Ir of at least one selected from the group consisting of IrO.sub.2, RuO.sub.2, IrRu.sub.xO.sub.y, IrNi.sub.xO.sub.y, IrSr.sub.xO.sub.y, and IrRu.sub.xNi.sub.yO.sub.z and arbitrary one or more elements M. However, an anode catalyst of the MEA in which the laminated electrolyte membrane 100 according to the embodiment is used is not limited to the above.

[0044] A method for manufacturing a carrierless porous catalyst layer according to the embodiment will be briefly described.

[0045] First, in the case of manufacturing a catalyst layer having a catalyst unit, a catalyst layer precursor is formed on a support by sputtering or evaporating a catalyst material and a pore-forming agent material at the same time. Next, the pore forming agent is removed to obtain an electrode. In the case of manufacturing a catalyst layer having a unit having a laminate structure including a gap layer, a catalyst layer precursor is formed on a support by alternately sputtering or evaporating a material containing a catalyst material and a pore-forming agent material. Next, the pore forming agent is removed to obtain an electrode.

[0046] The MEA according to the embodiment is prepared by combining an electrolyte membrane by using the above-described catalyst layer as at least either of the first electrode 3 or the second electrode 4. In general, the catalyst layer and the electrolyte membrane are bonded by heating and pressurizing. In this case, in the case where a forming support of the catalyst layer is a gas diffusion layer, the electrolyte membrane 100 is sandwiched with a support containing the catalyst layer and laminated as indicated in FIG. 3 and joined to obtain the MEA 200.

[0047] Further, in the case where the forming support of the catalyst layer is a transfer substrate, first, the catalyst layer is transferred from the transfer substrate to the electrolyte membrane 100, the catalyst layer is transferred to the electrolyte membrane 100, and the membrane catalyst layer assembly (catalyst coated membrane (CCM)) is prepared. Then, the CCM is laminated as indicated in FIG. 3 by sandwiching two gas diffusion supports and bonded by heating and pressuring to obtain the MEA 200. Alternatively, after transferring at least one of the catalyst layers to the electrolyte membrane 100, the gas diffusion layer may be disposed on the catalyst layer. These are laminated as indicated in FIG. 3 and joined by heating and pressurizing to obtain the MEA 200.

Third Embodiment

[0048] A water electrolysis cell according to a third embodiment includes a membrane electrode assembly, a cathode feed conductor, a separator, a gasket (seal), an anode feed conductor, a separator, and a gasket (seal). The membrane electrode assembly includes a first electrode, a second electrode, a hydrocarbon-based electrolyte membrane, and a composite electrolyte membrane. The composite electrolyte membrane is laminated with the hydrocarbon-based electrolyte membrane and contains a perfluorosulfonic acid-based electrolyte and a superstrong acid metal oxide having an acid function (H0) of 12 or less. Since highly efficient water electrolysis can be performed, the water electrolysis cell using a laminated electrolyte membrane according to the embodiment is preferable in that, when it is used for water electrolysis, membrane resistance of the electrolyte membrane is low, crossover is low, and resistance is low.

[0049] FIG. 5 is a cross-sectional view of a water electrolysis cell 300 according to the third embodiment. The water electrolysis cell 300 illustrated in FIGS. 4A to 4D includes a first electrode (cathode) 3, a second electrode (anode) 4, a laminated electrolyte membrane 100, a cathode feed conductor 5, a separator 6, an anode feed conductor 7, a separator 8, a gasket (seal) 9, and a gasket (seal) 10. Instead of the laminated electrolyte membrane 100, a laminated electrolyte membrane 101 may be used. Any type of anode feed conductors and cathode feed conductors may be used as long as gas and water can pass through. In addition, each of the feed conductors may be integrated with a separator. Specifically, the feed conductor is, for example, a feed conductor having a flow path through which water or gas flows in a separator and a feed conductor having a porous body, but is not limited thereto.

[0050] In the water electrolysis cell 300 illustrated in FIG. 5, an electrode (not illustrated) is connected to the cathode feed conductor 5 and the anode feed conductor 7, and a reaction occurs between the cathode and the anode. Water is supplied to the anode, and water is decomposed into protons, oxygen and electrons at the anode electrode. A support of the electrode and the feed conductor are porous bodies, and this porous body functions as a flow path plate. The generated water and unreacted water are discharged, and protons and electrons are used in a cathode reaction through the laminated electrolyte membrane 100. In the cathode reaction, protons and electrons react to produce hydrogen. Either one or both of the generated hydrogen and oxygen are used, for example, as fuel for a fuel cell. A membrane electrode assembly is held by the separators 6 and 8, and airtightness is maintained by gaskets (seals) 9 and 10.

[0051] The laminated electrolyte membrane 100 according to the embodiment is difficult to separate in water and therefore excellent in durability. In addition, the laminated electrolyte membrane 100 according to the embodiment is excellent in chemical resistance and has low membrane resistance, and therefore has low crossover and is excellent in decomposition efficiency.

Fourth Embodiment

[0052] A plurality of membrane electrode assemblies 200 or a plurality of water electrolysis cells is connected in series in a stack 400 according to a fourth embodiment illustrated in FIG. 6. Tightening plates 11 and 12 are attached to both ends of the water electrolysis cell.

Fifth Embodiment

[0053] A fifth embodiment relates to a water electrolysis apparatus. For the water electrolysis apparatus, a stack 400 according to the embodiment is used. The water electrolysis apparatus will be described with reference to a schematic diagram in FIG. 7. Water electrolysis single cells illustrated in FIG. 7 laminated in series are used as the water electrolysis stack 400. A power source 18 is attached to the water electrolysis stack 400, and a voltage is applied between an anode and a cathode. On the anode side of the water electrolysis stack 400, a gas-liquid separator 15 for separating generated gas and unreacted water and a mixing tank 14 are connected. To the mixing tank 14, water is sent by a pump 19 from an ion exchange water manufacturing device 13 which supplies water, and the water is circulated to the anode by mixing in the mixing tank 14 from the gas-liquid separator 15 through a check valve 20. Oxygen generated at the anode passes through the gas-liquid separator 15, and oxygen gas is obtained. On the other hand, on the cathode side, a hydrogen purification device 17 is continuously connected to a gas-liquid separator 16 to obtain high purity hydrogen. Impurities are discharged via a path including a valve 21 connected to the hydrogen purification device 17. To stably control an operating temperature, it is possible to control heating of the stack and the mixing tank and a current density during thermal decomposition.

[0054] Hereinafter, the above embodiments will be described in detail in examples.

EXAMPLES 1 TO 11 AND COMPARATIVE EXAMPLES 1 TO 4

Adjustment of Coating Solution for Composite Membrane

[0055] A coating solution for a composite membrane is adjusted by adding 20 g of ethanol to a predetermined amount of a fluorine-based electrolyte dispersion (20% nafion dispersion solution, Du Pont) in a polyhot, adding a superstrong acid oxide and a predetermined amount thereof, and adding 40 zirconia balls (diameter 5 mm), and dispersing them for 10 minutes by using Rentaro (Thinky Corporation). Compositions of the prepared dispersion in examples 1 to 11 and comparative examples 1 to 4 are summarized in Table 1. In example 7, 8 and comparative example 2, decomposer (hydrogen peroxide decomposer) is used for preparing dispersion.

Preparation of Superstrong Acid Oxide

[0056] Synthesis of MoO.sub.3/TiO.sub.2

[0057] An aqueous solution is adjusted in which hexammonium heptamolybdate tetrahydrate (manufactured by Wako Pure Chemical Industries, Ltd.) (NH.sub.4).sub.6Mo.sub.7O.sub.24, 4H.sub.2O is dissolved in water. The aqueous solution is mixed with a dispersion (containing 2 mL of concentrated HCl) in which titanium oxide (Super Titania F-6 and F-4, made by Showa Denko K.K.) TiO.sub.2 is dispersed in water. The mixture is evaporated to dryness at 80 C. to support ammonium molybdate on TiO.sub.2. The obtained precursor is dried at 100 C. for 6H and then calcined at 600 C. for 4H, and ammonium molybdate is thermally decomposed to obtain MoO.sub.3/TiO.sub.2. The composition of MoO.sub.3/TiO.sub.2 is 5/95 by a weight ratio.

[0058] Synthesis of WO.sub.3/TiO.sub.2

[0059] An aqueous solution is adjusted in which tungsten oxide (Wako Pure Chemical Industries, Ltd.) WO.sub.3 is dissolved in heated condensed ammonia aqueous solution (made by Wako Pure Chemical Industries, Ltd., 15% aqueous solution). This aqueous solution is mixed with a dispersion in which titanium oxide (Super Titania F-6 Showa Denko K.K.) TiO.sub.2 is dispersed in water. This aqueous solution is evaporated to dryness at 80 C. to support ammonium tungstate on TiO.sub.2. The obtained precursor is dried at 100 C. for 6H and then calcined at 700 C. for 4H, and ammonium tungstate is thermally decomposed to obtain WO.sub.3/TiO.sub.2.

[0060] Two kinds of compositions of WO.sub.3/TiO.sub.2 at a weight ratio of 5/95 and 10/90 are prepared.

[0061] Synthesis of VO.sub.3/TiO.sub.2

[0062] An aqueous solution is adjusted in which ammonium metavanadate (Wako Pure Chemical Industries, Ltd.) (NH.sub.4)VO.sub.3 is dissolved in hot water. The aqueous solution is mixed with a dispersion (containing 2 mL of concentrated HCl) in which titanium oxide (Super Titania F-6 and F-4, Showa Denko K.K.) TiO.sub.2 is dispersed in water. The mixture was evaporated to dryness at 80 C. to support ammonium metavanadate on TiO.sub.2. The obtained precursor was dried at 100 C. for 6H and then calcined at 600 C. for 4H, and ammonium metavanadate is thermally decomposed to obtain VO.sub.3/TiO.sub.2. The composition of MoO.sub.3/TiO.sub.2 is 5/95 by a weight ratio.

[0063] Synthesis of WO.sub.3/ZrO.sub.2

[0064] An aqueous solution is adjusted in which tungsten oxide (Wako Pure Chemical Industries, Ltd.) WO.sub.3 is dissolved in heated condensed ammonia aqueous solution (Wako Pure Chemical Industries, 15% aqueous solution). This aqueous solution is mixed with a dispersion in which zirconium oxide (Wako Pure Chemical Industries, Ltd.) ZrO.sub.2 is dispersed in water. This aqueous solution is evaporated to dryness at 80 C. to support ammonium tungstate on TiO.sub.2. The obtained precursor is dried at 100 C. for 6H and then calcined at 700 C. for 4H, and ammonium tungstate is thermally decomposed to obtain WO.sub.3/TiO.sub.2.

[0065] Two kinds of compositions of WO.sub.3/TiO.sub.2 at a weight ratio of 5/95 and 20/90 are prepared.

[0066] Synthesis of SO.sub.4/TiO.sub.2

[0067] A dispersion of titanium oxide is adjusted by mixing 9.500 g of titanium oxide (TiO.sub.2, Tayca, AMT-100) and 300 mL of water in a 1,000 mL beaker. Evaporation to dryness is performed by mixing 0.521 g of concentrated sulfuric acid (96%) with this dispersion, further adding water to make the total volume 400 mL, and stirring the solution by a hot stirrer set at 140 C. A precursor is pulverized and passed through a 106 m sieve, placed on a baking dish, and fired at 600 C. for 3 hours to obtain sulfuric acid-supported titanium oxide SO.sub.4/TiO.sub.2. Composition analysis by ICP analysis reveals that S is 0.64% (1.92% in terms of SO.sub.4), TiO.sub.2 is 95.0%, and the rest is moisture. Therefore, the SO.sub.4 supporting amount is 2.0% in a state where moisture is removed.

[0068] Synthesis of SO.sub.4/ZrO.sub.2

[0069] A dispersion of titanium oxide is adjusted by mixing 9.500 g of zirconium oxide (made by Wako Pure Chemical Industries, Ltd.) and 300 mL of water in a 1000 mL beaker. Evaporation to dryness is performed by mixing 1.01 g of concentrated sulfuric acid (96%) with this dispersion, further adding water to make the total volume 400 mL, and stirring the solution by a hot stirrer set at 140 C. A precursor is pulverized and passed through a 106 m sieve, placed on a baking dish, and fired at 600 C. for 3 hours to obtain sulfuric acid-supported titanium oxide SO.sub.4/TiO.sub.2. Composition analysis by ICP analysis reveals that S is 0.96% (2.88% in terms of SO.sub.4), TiO.sub.2 is 96.0%, and the rest is moisture. Therefore, the SO.sub.4 supporting amount is 3.0% in a state where moisture is removed.

TABLE-US-00001 TABLE 1A Coat- Ionomer Superstrong acid oxide ing Addi- Solid Addi- Solid solu- tion content tion content tion amount weight amount weight No. (g) % Type (g) % Example 1 S1 4.050 45.0 5% 0.990 55.0 VO.sub.3/TiO.sub.2 Example 2 S2 2.971 33.0 5% 1.206 67.0 WO.sub.3/TiO.sub.2 Example 3 S3 6.283 70.0 10% 0.542 30.0 WO.sub.3/TiO.sub.2 Example 4 S4 3.601 40.0 5% 1.080 60.0 MoO.sub.3/TiO.sub.2 Example 5 S5 3.150 35.0 5% 1.170 65.0 WO.sub.3/ZrO.sub.2 Example 6 S6 3.150 35.0 5% 1.170 65.0 .sup.WO.sub.3/SnO.sub.2 Example 7 S7 3.040 32.8 5% 1.207 65.3 WO.sub.3/TiO.sub.2 Example 8 S8 4.182 42.4 5% 0.901 50.0 WO.sub.3/TiO.sub.2 Example 9 S9 2.703 30.0 2% 1.260 70.0 .sup.SO.sub.4/TiO.sub.2 Example 10 S10 1.800 20.0 3% 1.440 80.0 SO.sub.4/ZrO.sub.2 Example 11 S11 7.204 80.0 20% 0.360 20.0 WO.sub.3/ZrO.sub.2 Comparative CS1 9.000 100.0 Nothing Example 1 Comparative CS2 1.350 15.0 10% 1.350 75.0 Example 2 WO.sub.3/TiO.sub.2 Comparative CS3 1.530 17.0 20% 1.494 83.0 Example 3 WO.sub.3/ZrO.sub.2 Comparative CS4 7.380 82.0 5% 0.324 18.0 Example 4 WO.sub.3/TiO.sub.2

TABLE-US-00002 TABLE 1B Decomposer Addition Solid amount content Type (g) weight % Example 1 Nothing Example 2 Nothing Example 3 Nothing Example 4 Nothing Example 5 Nothing Example 6 Nothing Example 7 CeO.sub.2 0.034 1.9 Example 8 MnO.sub.2 0.064 3.6 Example 9 Nothing Example 10 Nothing Example 11 Nothing Comparative Nothing Example 1 Comparative CeO.sub.2 0.18 10 Example 2 Comparative Nothing Example 3 Comparative Nothing Example 4

EXAMPLES 12 TO 25 AND COMPARATIVE EXAMPLES 5 TO 10

Preparation of Composite Laminated Membrane

[0070] A composite laminated membrane is prepared by spraying the above-described adjusted dispersion for a composite membrane on various membrane thickness aromatic hydrocarbon-based electrolyte membranes (EW400), drying the membranes at 60 C. for 10 minutes, drying at 130 C. for 10 minutes, and further drying at 180 C. for 10 minutes while pressurizing at 10 kg/cm.sup.2. Table 2 indicates the prepared various membranes in examples 12 to 25 and comparative examples 5 to 10.

COMPARATIVE EXAMPLE 11

[0071] A three-layered laminated membrane (comparative example 11) is prepared by stacking a nafion HP membrane, a 13 m membrane of the aromatic hydrocarbon-based electrolyte membrane, and a nafion HP membrane in this order and heating and compressing them at 180 C. for 10 minutes while pressurizing to 10 kg/cm.sup.2.

Immersion Test

[0072] Ion exchanged water is sufficiently poured in a beaker, and an immersion test is performed in which the above-described prepared composite laminated membrane is immersed for 5 minutes at room temperature. In Table 2, the case where the membrane is peeled off at an interface of the laminated membrane is marked with x, and the case where the membrane is not peeled off is marked with .

Preparation of Anode Electrode and Cathode Electrode

[0073] An anode electrode is prepared by sputtering IrNi.sub.xO.sub.y and a gap agent by reactive sputtering on a 200 m-thick titanium porous body, and etching, heating, and drying after acid treatment. An IrNi.sub.xO.sub.y catalyst layer is an Ir amount of 0.15 mg/cm.sup.2 (22 layers).

Preparation of Cathode Electrode

[0074] A cathode electrode is prepared by etching with acid and heating and drying after washing with water after sputtering on a Carpon Paper with a cathode electrode MPL (microporous layer) . A PtCo alloy catalyst is a platinum amount of 0.18 mg/cm.sup.2 (28 layers).

TABLE-US-00003 TABLE 2A Aromatic hydrocarbon-based Membrane electrolyte membrane thickness Mem- Membrane Coating of coating brane thickness solution membrane No. (nm) No. (m) Example 13 M1 40 S1 12 Example 14 M2 13 S2 20 Example 15 M3 40 S2 11 Example 16 M4 13 S3 23 Example 17 M5 40 S4 12 Example 18 M6 40 S5 13 Example 19 M7 40 S6 11 Example 20 M8 40 S7 12 Example 21 M9 13 S8 21 Example 22 M10 40 S9 12 Example 23 M11 40 S10 13 Example 25 M12 13 S11 20 Example 26 M13 13 S8 11 and 11 Comparative CM1 13 Nothing Example 5 Comparative CM2 40 Nothing Example 6 Comparative CM3 40 CS1 13 Example 7 Comparative CM4 40 CS2 12 Example 8 Comparative CM5 40 CS3 14 Example 9 Comparative CM6 40 CS4 12 Example 10 Comparative CM7 13 Paste nafion HP Example 11 membranes on both sides

TABLE-US-00004 TABLE 2B Accumulated membrane Immersion structure test Example 13 Two layers (one side coating membrane) Example 14 Two layers (one side coating membrane) Example 15 Two layers (one side coating membrane) Example 16 Two layers (one side coating membrane) Example 17 Two layers (one side coating membrane) Example 18 Two layers (one side coating membrane) Example 19 Two layers (one side coating membrane) Example 20 Two layers (one side coating membrane) Example 21 Two layers (one side coating membrane) Example 22 Two layers (one side coating membrane) Example 23 Two layers (one side coating membrane) Example 25 Two layers (one side coating membrane) Example 26 Three layers (double coated) Comparative Single layer (single Example 5 membrane) Comparative Single layer (single Example 6 membrane) Comparative Two layers x Example 7 Comparative Two layers Example 8 Comparative Two layers Example 9 Comparative Two layers Example 10 Comparative Three layers x Example 11

EXAMPLES 25 TO 37 AND COMPARATIVE EXAMPLES 13 TO 17

Preparation of Membrane Electrode Assembly

[0075] Each of the anode electrode and the cathode electrode are cut to 20 mm square each. The anode electrode, a laminated electrolyte membrane, and the cathode electrode are sequentially stacked and pressure-bonded by hot pressing (50 kg, 165 C., 4 minutes), and then cooled to room temperature to prepare an MEA. The process is summarized in Table 3. However, when the composite laminated membrane has two layers, an aromatic hydrocarbon-based electrolyte membrane side is prepared as a cathode electrode side.

COMPARATIVE EXAMPLE 12

[0076] An MEA (comparative example 12) is prepared by using nafion 115 as a membrane in the same manner as preparation conditions for the above-described MEA.

Evaluation of Water Electrolysis Performance

[0077] In a titanium water electrolysis cell, as a feed conductor (integrated with a separator) of an anode and a cathode, a flow channel plate of titanium is used, and a single cell (anode & cathode; straight channel) having an electrode area of 4 cm.sup.2 is used. The cell temperature is 80 C. at atmospheric pressure, and the temperature is maintained by heating by a heater, and ion-exchanged water is used by circulating, to the anode, several times the amount of water necessary for water decomposition. Water electrolysis is performed at a cell temperature of 80 C. by using an electronic load device manufactured by Kikusui Corporation at a current density of 2 A/cm.sup.2. Decomposition voltages of water and AC impedance resistance at 1 KHz in such a case are summarized in Table 3.

Measurement of Hydrogen Crossover

[0078] Water decomposition is carried out at a constant current of the above-described water electrolysis conditions, gas coming out from the anode side is separated by water and repaired for 30 minutes, and a hydrogen concentration is measured by GC-MS. Measurement results are indicated in Table 3.

TABLE-US-00005 TABLE 3 Initial Voltage After 50 h Membrane (V) @2 Resistance Voltage (V) Resistance Hydrogen leak MEA No. A/cm.sup.2 (m) @2 A/cm.sup.2 (m) amount (%) Example 27 M1 1.83 30.2 1.82 27.2 0.12 Example 28 M2 1.78 23.2 1.81 23.0 0.30 Example 29 M3 1.81 27.0 1.83 27.5 0.13 Example 30 M4 1.78 23.2 1.81 23.0 0.29 Example 31 M5 1.82 27.5 1.83 28.0 0.11 Example 32 M6 1.84 30.4 1.83 29.5 0.10 Example 33 M7 1.85 31.2 1.83 29.7 0.11 Example 34 M8 1.87 31.2 1.83 27.5 0.12 Example 35 M9 1.77 23.1 1.80 24.0 0.29 Example 36 M10 1.85 31.2 1.83 29.5 0.09 Example 37 M11 1.87 31.2 1.84 28.5 0.14 Example 38 M12 1.78 22.2 1.81 23.0 0.32 Example 39 M13 1.80 25.6 1.81 26.1 0.21 Comparative nafion115 1.90 35.0 1.86 31.2 0.82 Example 12 Comparative CM1 1.69 16.7 An abnormal value is 0.40 (initial) Example 13 indicated by thinning or pinhole Comparative CM2 1.75 21.2 An abnormal value is 0.18 (initial) Example 14 indicated by thinning or pinhole Comparative CM4 1.93 35.1 1.92 36.2 0.14 Example 15 Comparative CM5 Cannot measure Cannot measure Example 16 Comparative CM6 1.80 28.0 Cannot measure Example 17

[0079] As indicated in the comparative examples 7 and 11 in Table 2, interface peeling occurred in a laminated membrane in which a fluorine-based electrolyte membrane is simply laminated on an aromatic hydrocarbon-based electrolyte membrane. On the other hand, in the composite laminated membrane, peeling is not observed in an immersion test. As indicated in Table 3, it is revealed that when the aromatic hydrocarbon-based electrolyte membrane is used alone, durability is not sufficient in water electrolysis characteristics. However, it is revealed that durability of the composite laminated membrane is improved without problems after 50 h. In addition, in any case, the MEA using the composite membrane is highly efficient because crossover is low, membrane resistance is low, and a voltage is low in comparison with the comparative example 12 in which nafion 115, standard used in PEM type water electrolysis, is used.

[0080] Here, some elements are expressed only by element symbols thereof.

[0081] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.