# US 8,147,745 B2 · Process for producing fiber and method for producing catalyst layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,147,745 B2 - Document ID: US8147745B2 - Status: Granted - Kind: B2 - Application number: 12/578,693 - Filed: 2009-10-14 - Published: 2010-04-22 - Granted: 2012-04-03 - Earliest claimed: 2008-10-17 - Assignees: Asahi Glass Company, Limited - Inventors: Ichiro Terada; Seigo Kotera; Katsuya Fujii; Hiroyuki Watabe; Hiroshi Uyama; Chie Matsubara - Web page: https://patentgrep.com/patent/US8147745B2 ## CPC - D01F 1/09: for making electroconductive or anti-static filaments - D01D 5/04: Dry spinning methods {(D01D5/0038 takes precedence)} - D01D 5/14: with flowing liquid {or gaseous} stretching media {, e.g. solution-blowing} - D01F 6/32: comprising halogenated hydrocarbons as the major constituent - D01F 8/10: with at least one other macromolecular compound obtained by reactions only involving carbon-to-carbon unsaturated bonds as constituent - H01M 4/8803: {Supports for the deposition of the catalytic active composition (H01M4/90 takes precedence)} - H01M 2008/1095: {Fuel cells with polymeric electrolytes} - Y02E 60/50: Fuel cells - D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS - D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract To provide a process whereby an ultrafine fiber of a fluorinated ion exchange resin can be produced easily at low cost, and a method whereby a catalyst layer having a high gas diffusion property can be produced easily at low cost. A process for producing a fiber by spinning a spinning solution containing a fluorinated ion exchange resin and a solvent by a dry spinning method, or producing an electrically conductive composite fiber by spinning n types (where n is an integer of at least 2) of spinning solutions, of which at least one type contains a fluorinated ion exchange resin and a solvent, and at least one type contains an electrically conductive material and a solvent, simultaneously by a dry spinning method, wherein the spinning solution which is being spun by the dry spinning method, is stretched by a gas stream; and a method for producing a catalyst layer, which comprises accumulating the fiber produced by such a process to form a non-woven fabric thereby to obtain a catalyst layer having the non-woven fabric. ## Claims ### Claim 1 A process for producing a fiber by a spinning method which comprises: discharging n types of spinning solutions, wherein n is an integer of at least 2, of which at least one type comprises a fluorinated ion exchange resin and a solvent, simultaneously from discharge nozzles, and evaporating solvents from the discharged n types of spinning solutions, wherein the n types of spinning solutions, which are combined and spun by the spinning method, are stretched by a gas stream, and wherein at least two of the n types of spinning solutions are discharged from different discharge nozzles. ### Claim 2 (depends on 1) The process for producing a fiber according to claim 1, wherein at least one type of the spinning solutions comprises an electrically conductive material and a solvent. ### Claim 3 (depends on 2) The process for producing a fiber according to claim 2, wherein the electrically conductive material is a catalyst comprising a metal. ### Claim 4 A process for producing an electrically conductive composite fiber by a spinning method, the process comprises: discharging n types of spinning solutions, wherein n is an integer of at least 2, of which at least one type comprises a fluorinated ion exchange resin and a solvent, and at least one type comprises an electrically conductive material and a solvent, simultaneously from discharge nozzles, and evaporating the solvents from the discharged n types of spinning solutions, wherein the n types of spinning solutions, which are combined and spun by the spinning method, are stretched by a gas stream, and wherein the n types of spinning solutions are discharged from n different discharge nozzles. ### Claim 5 (depends on 4) The process for producing an electrically conductive composite fiber according to claim 4, wherein the electrically conductive material is a catalyst comprising a metal. ### Claim 6 (depends on 3) A method for producing a catalyst layer for a membrane/electrode assembly for a polymer electrolyte fuel cell, which comprises accumulating the fiber produced by the process as defined in claim 3 to form a non-woven fabric, thereby obtaining a catalyst layer having the non-woven fabric. ### Claim 7 (depends on 5) A method for producing a catalyst layer for a membrane/electrode assembly for a polymer electrolyte fuel cell, which comprises accumulating the fiber produced by the process as defined in claim 5 to form a non-woven fabric, thereby obtaining a catalyst layer having the non-woven fabric. ### Claim 8 (depends on 1) The process for producing a fiber according to claim 1, wherein the gas stream is parallel or oblique to the direction of the spinning solutions from the discharge nozzles. ### Claim 9 (depends on 1) The process for producing a fiber according to claim 1, wherein the gas stream is pressurized. ### Claim 10 (depends on 1) The process for producing a fiber according to claim 1, wherein the gas stream is an inert gas stream. ### Claim 11 (depends on 1) The process for producing a fiber according to claim 1, wherein a blowoff amount of the gas stream is at least 0.5 L/min and at most 100 L/min. ### Claim 12 (depends on 4) The process for producing a fiber according to claim 4, wherein the gas stream is parallel or oblique to the direction of the spinning solution from the discharge nozzles. ### Claim 13 (depends on 4) The process for producing a fiber according to claim 4, wherein the gas stream is pressurized. ### Claim 14 (depends on 4) The process for producing a fiber according to claim 4, wherein the gas stream is an inert gas stream. ### Claim 15 (depends on 4) The process for producing a fiber according to claim 4, wherein a blowoff amount of the gas stream is at least 0.5 L/min and at most 100 L/min. ### Claim 16 (depends on 1) The process for producing a fiber according to claim 1, wherein the discharge nozzles are surrounded by a gas stream blowing nozzle. ### Claim 17 (depends on 16) The process for producing a fiber according to claim 16, wherein each of the nozzles discharge one of the n types of the spinning solutions, and wherein the nozzles are tubes.