Diaphragm for direct-liquid fuel cell and process for producing the same

A process for producing a membrane for direct-liquid fuel cell, the membrane being comprised of a layered cation-exchange membrane whose one side is constituted by A) a layer formed by filling, in the pores of a low-porosity porous membrane having an average pore diameter of 0.005 to 10 μm and a porosity of 10 to 50%, a crosslinked, hydrocarbon-based cation-exchange resin having a cation exchange capacity of 0.1 to 6.0 mmol/g, a water content of 2 to 150% by mass at a relative humidity of 50% RH (25° C.) and a water content of 14 to 250% by mass at a relative humidity of 100% RH (25° C.) and whose other side is constituted by B) a layer formed by filling, in the pores of a high-porosity porous membrane having an average pore diameter of 0.01 to 50 μm and a porosity higher, by 7% or more, than that of the low-porosity porous membrane, the same crosslinked, hydrocarbon-based cation-exchange resin as filled in the pores of the low-porosity porous membrane of the membrane layer A), and the layered cation-exchange membrane having an electrical resistance of 0.5 to 0.01 Ω·cm2 in a 1 mol/L aqueous sulfuric acid solution at 25° C.,

• the process being characterized by contacting a polymerizable composition containing a polymerizable monomer having a functional group into which cation-exchange group can be introduced or a cation-exchange group-containing polymerizable monomer, 0.5 to 40 mol %, relative to 100 mols of the polymerizable monomer, of a crosslinkable polymerizable monomer, and an effective amount of a polymerization initiator, with a layered porous membrane constituted by a low-porosity porous membrane having an average pore diameter of 0.005 to 10 μm and a porosity of 10 to 50% and a high-porosity porous membrane having an average pore diameter of 0.01 to 50 μm and a porosity higher, by 7% or more, than that of the low-porosity porous membrane, to fill the polymerizable composition in the pores of the layered porous membrane, then polymerizing and curing the composition, thereafter introducing a cation-exchange group as necessary.

A process for producing a membrane for direct-liquid fuel cell, the membrane being comprised of a layered cation-exchange membrane whose one side is constituted by A) a cation-exchange membrane layer of low water content type having a water content of 1 to 15% by mass at a relative humidity of 50% RH (25° C.) and whose other side is constituted by B) a cation-exchange membrane layer of high water content type having, at a relative humidity of 100% RH (25° C.), a water content which is higher, by 3% by mass or more, than the water content of the cation-exchange membrane layer of low water content type at a relative humidity of 100% RH (25° C.), the layered cation-exchange membrane having an electrical resistance of 0.5 to 0.01 Ω·cm2 in a 1 mol/L aqueous sulfuric acid solution at 25° C.,

• the process being characterized by hot-pressing
• a) a cation-exchange membrane of low water content type having a water content of 1 to 15% by mass at a relative humidity of 50% RH (25° C.) and an electrical resistance of 0.3 to 0.006 Ω·cm2 in a 1 mol/L aqueous sulfuric acid solution at 25° C., and
• b) a cation-exchange membrane of high water content type having, at a relative humidity of 100% RH (25° C.), a water content higher by 3% by mass or more than that of the cation-exchange membrane of low water content type at a relative humidity of 100% RH (25° C.) and an electrical resistance of 0.2 to 0.004 Ω·cm2 in a 1 mol/L aqueous sulfuric acid solution at 25° C.