Membrane Electrode Assembly, Method of Manufacturing the Same, Fuel Battery, and Electronic Device

• US 20080014495A1
• Filed: 09/12/2005
• Published: 01/17/2008
• Est. Priority Date: 09/21/2004
• Status: Abandoned Application

• Current Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Kambara, Hironori, Yoshie, Tomohisa, Fujita, Toshiyuki, Teraoka, Katsumi, Saito, Kotaro, Ochi, Norihiro
• Application Number:
  US11/661,801
• Publication Number:
  US 20080014495A1
• Time in Patent Office: Days
• US Class Current: 429/44
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/8821 Wet proofing
• CPC Class Codes: H01M 4/8825 Methods for deposition of the catalytic active composition
• CPC Class Codes: H01M 8/0247 characterised by the form characterised by a channel configuration H01M8/0258
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1011 Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
• CPC Class Codes: H01M 8/2455 with liquid, solid or electrolyte-charged reactants
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

There are provided a membrane electrode assembly (1) formed by stacking an extraction electrode (6a, 6b), a catalyst layer (5a, 5b), and an electrolyte membrane (2) in this order and integrating the same, and a method of manufacturing the membrane electrode assembly (1) including the steps of forming an electrode base material by fixing the extraction electrode (6a, 6b) at one surface of a base, forming the catalyst layer (5a, 5b) on the extraction electrode (6a, 6b), and integrating the electrode base material having the catalyst layer (5a, 5b) formed thereon with the electrolyte membrane (2). By such a method, the membrane electrode assembly can be manufactured with high yield, with favorable electrical contact maintained between the catalyst layer and the extraction electrode, without their being pressed and fixed by clamping from outside. Accordingly, it is possible to implement a fuel battery that can produce high output and can be downsized.

Claims

1. (canceled)

2. A membrane electrode assembly formed by successively stacking a catalyst layer, an extraction electrode, and a porous base at an electrolyte membrane, and integrating the catalyst layer, the extraction electrode, and the porous base with the electrolyte membrane.

3. The membrane electrode assembly according to claim 2, wherein the extraction electrode has an opening portion, and at least one selected from the group consisting of the porous base and the catalyst layer penetrates into the opening portion.

4. The membrane electrode assembly according to claim 2, wherein the porous base has electrical conductivity.

5. The membrane electrode assembly according to claim 2, wherein the porous base has a water-repellent surface.

7. The membrane electrode assembly according to claim 2, wherein the extraction electrode is integrated with the catalyst layer with an adhesion layer interposed therebetween.

8. The membrane electrode assembly according to claim 2, wherein the catalyst layer is configured with a first catalyst layer and a second catalyst layer placed in an order allowing the first catalyst layer to be at a larger distance from the electrolyte membrane than the second catalyst layer is.

9. The membrane electrode assembly according to claim 8, wherein the first catalyst layer has a higher void ratio than the second catalyst layer has.

10. The membrane electrode assembly according to claim 2, wherein the extraction electrode contains at least one element selected from the group consisting of Ti, Au, Ag, Pt, Nb, Ni, Cu, Si, W and Al.

11. The membrane electrode assembly according to claim 2, wherein the extraction electrode is either of a metal mesh and a stamped metal plate each having a surface subjected to a conductive, corrosion-resistant treatment.

12. The membrane electrode assembly according to claim 2, wherein the extraction electrode is formed by any of an ink jet printing method, a CVD method, a vapor deposition method, a plating method, a sol-gel method, a sputtering method, and a screen printing method.

13. A fuel battery having the membrane electrode assemblies recited in claim 2 arranged in a plane direction and wired electrically.

14. An electronic device having the fuel battery recited in claim 13 mounted thereon.

20. The membrane electrode assembly according to claim 2, wherein the porous base is non-conductive.

22. The membrane electrode assembly according to claim 7, wherein an adhesion layer is formed to be placed at a peripheral portion of the catalyst layer.

6. (canceled)

15. A method of manufacturing a membrane electrode assembly, comprising the steps of:

forming an electrode base material by fixing an extraction electrode at one surface of a base;

forming a catalyst layer on the extraction electrode; and

integrating the electrode base material having the catalyst layer formed thereon with an electrolyte membrane.

16. The method of manufacturing the membrane electrode assembly according to claim 15, wherein the step of integrating the electrode base material having said catalyst layer formed thereon with the electrolyte membrane is a step of integrating the electrode base material having the catalyst layer formed thereon with a Catalyst Coated Membrane (CCM), which is the electrolyte membrane having a catalyst layer transferred thereto.

17. The method of manufacturing the membrane electrode assembly according to claim 15, wherein a porous base having a water-repellent layer formed at a surface to be joined to the extraction electrode is used as the base.

18. The method of manufacturing the membrane electrode assembly according to claim 15, wherein a porous base having a conductive layer formed at a surface to be joined to the extraction electrode is used as the base.

19. The method of manufacturing the membrane electrode assembly according to claim 15, wherein the method includes a step of forming irregularities at least one of a surface of the catalyst layer and a surface of the electrolyte membrane, both of the surfaces being to be bonded together, as a pretreatment of the step of integrating the electrode base material with the electrolyte membrane.

21. A fuel battery having a plurality of cells connected electrically, each of the plurality of cells being formed by successively integrating a plurality of catalyst layers and an extraction electrode with a single electrolyte membrane.