Polymer electrolyte fuel cell and manufacturing method thereof
A polymer electrolyte fuel cell comprises a catalyst layer; a cation exchange resin provided in the catalyst layer; a proton conductive path provided in the cation exchange resin; a carbon material provided in the catalyst layer; and a catalyst metal provided in the catalyst layer. 50 mass % or more of the catalyst metal is loaded on the contact surface between the proton conductive path and the carbon material, and the porosity of the catalyst layer is 65% to 87.5%.
1 . A polymer electrolyte fuel cell comprising:
a catalyst layer;
a cation exchange resin provided in said catalyst layer;
a proton conductive path provided in said cation exchange resin;
a carbon material provided in said catalyst layer; and
a catalyst metal provided in said catalyst layer,
wherein 50 mass % or more of said catalyst metal is loaded on a contact surface between said proton conductive path and said carbon material, and
a porosity of said catalyst layer is 65% to 87.5%.
2 . The polymer electrolyte fuel cell according to claim 1 , wherein the porosity of said catalyst layer is 70% to 85%.
3 . The polymer electrolyte fuel cell according claim 1 , wherein said catalyst metal contains a platinum group metal.
4 . The polymer electrolyte fuel cell according to claim 2 , wherein said catalyst metal contains a platinum group metal.
5 . A manufacturing method of the polymer electrolyte fuel cell according to claim 1 , comprising the steps of:
a first process for adsorbing a cation of the catalyst metal to a fixed ion of said cation exchange resin in a mixture of the carbon material and the cation exchange resin;
a second process for reducing said cation after said first process so as to manufacture a mixture X which contains said cation exchange resin, said carbon material and said catalyst metal;
a third process for curing a slurry which contains said mixture X, a substance soluble in acid and a solvent, applied onto a substrate after said second process so as to manufacture a layered product of a catalyst layer containing said substance, and said substrate;
a fourth process for joining said catalyst layer to a cation exchange membrane after said third process so as to manufacture an assembly of said cation exchange membrane and a catalyst electrode; and
a fifth process for bringing said catalyst layer into contact with acid after said fourth process so as to dissolve said substance.
6 . The manufacturing method of the polymer electrolyte fuel cell according to claim 5 , wherein said substance comprises metal powder or inorganic compound powder.
7 . The manufacturing method of the polymer electrolyte fuel cell according to claim 5 , wherein said substance comprises nickel powder or calcium carbonate powder.
8 . The manufacturing method of the polymer electrolyte fuel cell according to claim 5 , wherein said acid in said fifth process comprises sulfuric acid or nitric acid.
9 . The manufacturing method of the polymer electrolyte fuel cell according to claim 5 , wherein said cation of said catalyst metal in said first process contains a platinum group metal.
10 . A manufacturing method of the polymer electrolyte fuel cell comprising the steps of:
a first process for substituting a cation of a catalyst metal for a cation exchange resin having a fixed anion bonded with a hydrogen ion and said hydrogen ion in a mixture with a carbon material, in a solution;
a second process for decreasing a hydrogen ion concentration of said solution after said first process;
a third process for reducing said cation after said first process so as to manufacture a mixture X containing said cation exchange resin, said carbon material and said catalyst metal;
a fourth process for curing a slurry which contains said mixture X, a substance soluble in acid and a solvent, applied onto a substrate after said second and third processes so as to manufacture a layered product of a catalyst layer containing said substance, and said substrate;
a fifth process for joining said catalyst layer to a cation exchange membrane after said fourth process so as to manufacture an assembly of said cation exchange membrane and a catalyst electrode; and
a sixth process for bringing said catalyst layer into contact with acid after said fifth process so as to dissolve said substance.
11 . The manufacturing method of the polymer electrolyte fuel cell according to claim 10 , wherein said substance comprises metal powder or inorganic compound powder.
12 . The manufacturing method of thepolymer electrolyte fuel cell according to claim 10 , wherein said substance comprises nickel powder or calcium carbonate powder.
13 . The manufacturing method of the polymer electrolyte fuel cell according to claim 10 , wherein said acid in said sixth process comprises sulfuric acid or nitric acid.
14 . The manufacturing method of the polymer electrolyte fuel cell according to claim 10 , wherein said cation of said catalyst metal in said first process contains a platinum group metal.