# US 12,006,216 B2 · Mesoporous carbon and manufacturing method of the same, and polymer electrolyte fuel cell

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- Number: US 12,006,216 B2
- Document ID: US12006216B2
- Status: Granted
- Kind: B2
- Application number: 17/105,417
- Filed: 2020-11-25
- Published: 2021-06-03
- Granted: 2024-06-11
- Earliest claimed: 2019-11-29
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Naoki Hasegawa; Kazuhisa Yano; Tomohiro Takeshita; Rui Imoto; Kumiko Nomura
- Web page: https://patentgrep.com/patent/US12006216B2

## CPC

- C01B 32/05: Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
- C01B 32/20: Graphite
- H01M 4/8605: {Porous electrodes}
- H01M 4/8803: {Supports for the deposition of the catalytic active composition (H01M4/90 takes precedence)}
- H01M 4/8817: {Treatment of supports before application of the catalytic active composition (coated porous composites H01M8/0245)}
- H01M 4/926: {on carbon or graphite}
- H01M 4/96: Carbon-based electrodes
- C01P 2004/60: Particles characterised by their size
- C01P 2004/64: Nanometer sized, i.e. from 1-100 nanometer
- C01P 2006/11: Powder tap density
- C01P 2006/14: Pore volume
- C01P 2006/16: Pore diameter
- H01M 2004/8689: {Positive electrodes}
- H01M 2008/1095: {Fuel cells with polymeric electrolytes}
- H01M 2300/0082: Organic polymers
- H01M 2300/0085: Immobilising or gelification of electrolyte
- Y02E 60/50: Fuel cells
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Mesoporous carbon has a beaded structure in which primary particles with mesopores are linked. In the mesoporous carbon, an average primary particle size is 7 nm or more and 300 nm or less, a pore diameter is 2 nm or more and 10 nm or less, an average thickness of pore walls is 3 nm or more and 15 nm or less, a pore volume is 0.2 mL/g or more and 3.0 mL/g or less, and a tap density is 0.03 g/cm3 or more and 0.3 g/cm3 or less. In a polymer electrolyte fuel cell, the mesoporous carbon is used as a catalyst carrier for at least an air electrode catalyst layer. The mesoporous carbon can be obtained by impregnating mesoporous silica satisfying a predetermined condition with a carbon source, performing polymerization and carbonization, and removing a template.

## Claims

### Claim 1

A polymer electrolyte fuel cell, comprising:
an air electrode catalyst layer including mesoporous carbon as a catalyst carrier, wherein the mesoporous carbon further comprising:
a beaded structure in which primary particles with mesopores are linked, wherein:
an average primary particle size of the mesoporous carbon is 7 nm or more and 300 nm or less;
a pore diameter of the mesopores is 2 nm or more and 10 nm or less;
an average thickness of pore walls of the mesopores is 3 nm or more and 15 nm or less;
a pore volume of the mesoporous carbon is 0.2 mL/g or more and 3.0 mL/g or less; and
a tap density of the mesoporous carbon is 0.03 g/cm3 or more and 0.3 g/cm3 or less.

### Claim 2 (depends on 1)

The polymer electrolyte fuel cell according to claim 1, wherein the average primary particle size is 10 nm or more and 250 nm or less.

### Claim 3 (depends on 1)

The polymer electrolyte fuel cell according to claim 1, wherein the average thickness of the pore walls is 3.5 nm or more and 10 nm or less.

### Claim 4 (depends on 1)

The polymer electrolyte fuel cell according to claim 1, wherein the pore volume is 0.5 mL/g or more and 2.5 mL/g or less.

### Claim 5 (depends on 1)

The polymer electrolyte fuel cell according to claim 1, wherein the tap density is 0.03 g/cm3 or more and 0.2 g/cm3 or less.

### Claim 6 (depends on 1)

The polymer electrolyte fuel cell according to claim 1, wherein the mesoporous carbon is obtained by performing a graphitization treatment at a temperature higher than 1500° C.

### Claim 7

A polymer electrolyte fuel cell, comprising:
an air electrode catalyst layer including mesoporous carbon as a catalyst carrier, wherein the mesoporous carbon further comprising:
a beaded structure in which primary particles with mesopores are linked, wherein:
an average primary particle size of the mesoporous carbon is 7 nm or more and 300 nm or less;
a pore diameter of the mesopores is 2 nm or more and 10 nm or less;
an average thickness of pore walls of the mesopores is 3 nm or more and 15 nm or less;
a pore volume of the mesoporous carbon is 0.2 mL/g or more and 3.0 mL/g or less; and
a tap density of the mesoporous carbon is 0.03 g/cm3 or more and 0.3 g/cm3 or less,
wherein the average primary particle size is 10 nm or more and 250 nm or less, and
wherein the average thickness of the pore walls is 3.5 nm or more and 10 nm or less.