EP1790026A2 - Membrane-electrode unit and fuel elements with increased service life - Google Patents

Abstract

The invention relates to a membrane-electrode unit comprising a) two electrochemically active electrodes (1, 3) divided by a polymer electrolytic membrane (5), wherein the surfaces of said polymer electrolytic membrane (5) are in contact with the electrodes (1, 3) in such a way that the first electrode (1) partially or entirely covers the front side of the polymer electrolytic membrane (5) and the second electrode (3) partially or entirely covers the rear side thereof, b) a sealing material (7, 9) is applied to the front and rear sides of the polymer electrolytic membrane (5), wherein the polymer electrolytic membrane (5) is provided with one or several recesses (11) and the sealing material (7) applied to the front side of the polymer electrolytic membrane (5) is in contact with the sealing material (9) applied to the rear side thereof. A method for producing said membrane-electrode unit and fuel cells provided therewith are also disclosed.

Description

description

Membrane electrode assemblies and fuel cells with increased lifetime

The present invention relates to membrane-electrode assemblies and

Increased life fuel cells having two electrochemically active electrodes separated by a polymer electrolyte membrane.

In polymer electrolyte membrane (PEM) fuel cells, sulfonic acid-modified polymers are currently used almost exclusively as proton-conducting membranes. Here are predominantly perfluorinated polymers application. A prominent example of this is Nafion ™ by DuPont de Nemours, Willmington USA. Proton conduction requires a relatively high water content in the membrane, typically 4-20 molecules of water per sulfonic acid group. The necessary water content, but also the stability of the polymer in

Combined with acidic water and the reaction gases hydrogen and oxygen, the operating temperature of the PEM fuel cell stacks usually limited to 80 - 100 ⁰ C. Under pressure, the operating temperatures can be increased to> 120 ⁰ C. Otherwise, higher operating temperatures can not be realized without a power loss of the fuel cell. At temperatures that are above the dew point of water for a given pressure level, the membrane dries completely and the fuel cell no longer supplies electrical energy as the resistance of the membrane increases to such high levels that no appreciable current flow occurs.

An integrated seal membrane-electrode assembly based on the technology set forth above is described, for example, in US 5,464,700. In the outer region of the membrane-electrode unit, on the surfaces of the membrane not covered by the electrodes, films of elastomers are provided, which at the same time constitute the seal to the bipolar plates and to the exterior space.

By this measure, a saving of very expensive Nafion ^® membrane material can be achieved. Further advantages achieved by this construction relate to the contamination of the membrane. An improvement in the

Long-term stability is not shown in US 5,464,700. This also results from the very low operating temperatures. In the description of the invention as set forth in US 5,464,700, it is noted that the operating temperature of the cell is equal to 80 ⁰ C is less restricted to temperatures. The technique described herein is therefore not suitable for fuel cells with operating temperatures above 100 ⁰ C. _Λ

For technical reasons, however, higher operating temperatures than 100 ⁰ C in the fuel cell are desirable. The activity of the precious metal based catalysts contained in the membrane electrode assembly (MEU) is significantly better at high operating temperatures. In particular, when using so-called reformates of hydrocarbons significant amounts of

Carbon monoxide contained in the reformer gas, which usually must be removed by a complex gas treatment or gas cleaning. At high operating temperatures, the tolerance of the catalysts to the CO impurities increases.

Furthermore, heat is generated during the operation of fuel cells. However, cooling of these systems to below 80 ⁰ C can be very expensive. Depending on the power output, the cooling devices can be made much simpler. This means that in fuel cell systems that are operated at temperatures above 100 ^° C, the waste heat can be made significantly more usable and thus the fuel cell system efficiency can be increased through electricity-heat coupling.

In order to reach these temperatures, membranes with new conductivity mechanisms are generally used. One approach to this is the use of

Membranes that show electrical conductivity without the use of water. The first promising development in this direction is set forth in WO96 / 13872.

This document also describes a first method for producing membrane

Electrodes units described. In this case, two electrodes are pressed onto the membrane, which cover only a part of the two main surfaces of the membrane. On the remaining free part of the main surfaces of the membrane, a PTFE seal is pressed in the cell, so that the gas chambers of anode and cathode are sealed against each other and against the environment.

Another high-temperature fuel cell is disclosed in JP-A-2001-608282. Herein, a membrane-electrode assembly is shown, which is provided with a polyimide seal. The problem with this structure, however, is that for sealing two membranes are necessary, between which a sealing ring made of polyimide is provided. Since the thickness of the membrane for technical reasons must be chosen as low as possible, the thickness of the sealing ring between the two membranes described in JP-A-2001 -196082 is extremely limited. In long-term experiments, it was found that such a structure is also not stable over a period of more than 1000 hours. From the document DE 10235360 a membrane-electrode unit is known which contains polyimide layers for sealing. These polyimide layers may optionally be provided with fluoropolymers to improve contact and thus further increase the long-term stability of the membrane-electrode assembly.

The aforementioned membrane-electrode assemblies are generally connected to planar bipolar plates into which channels are milled for gas flow. Since the membranes are partially of greater thickness than the seals described above, a further seal, usually made of PTFE, is inserted between the seal of the membrane-electrode assemblies and the bipolar plates.

It has now been found that the life of the fuel cells described above is limited.

The object of the present invention was therefore to provide improved membrane electrode assemblies and the fuel cells operated therewith, which should preferably have the following properties:

• The fuel cells should last as long as possible. • The fuel cells should be able to be used at operating temperatures which are as high as possible, in particular above 100 ^° C.

• Single cells should show consistent or improved performance over the longest possible period of operation.

• After a long period of operation, the fuel cells should have as high a quiescent voltage as possible and as little gas penetration as possible (gas cross-over). Furthermore, they should be able to be operated at the lowest possible stoichiometry.

• The fuel cells should, if possible, do without additional fuel gas humidification. • The membrane electrode units should be permanent or changing

Pressure differences between the anode and cathode can withstand the best possible.

• In particular, membrane electron units should be robust to different operating conditions (T, p, geometry, etc.) to maximize overall reliability.

• Membrane electrode assemblies should be easy to produce, on a large scale and at low cost.

These objects are achieved by membrane electrode assemblies with all features of claim 1. The present invention accordingly provides a membrane-electrode assembly comprising a) two electrochemically active electrodes which are separated by a polymer-electrolyte membrane, the surfaces of the polymer-electrolyte membrane being in contact with the electrodes such that the first electrode the front side of the polymer electrolyte membrane and the second electrode the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially covered, b) sealing material on the front and the back of the polymer electrolyte membrane, wherein the polymer electrolyte membrane has one or more recesses and the sealing material on the front side of the polymer electrolyte membrane with the sealing material on the back of the polymer electrolyte membrane in. Contact stands.

For the purposes of the present invention suitable polymer electrolyte membranes are known per se and are not subject to any restriction. Rather, all proton-conductive materials are suitable. Preferably, however, membranes are used which comprise acids, which acids may be covalently bound to polymers. Furthermore, a sheet material may be doped with an acid to form a suitable membrane. Furthermore, gels, in particular polymer gels, can also be used as the membrane, with polymer membranes which are particularly suitable for the present purposes being described, for example, in DE 102 464 61.

These membranes may be inter alia by swelling flat materials, for example a polymeric film, with a liquid comprising acidic compounds, or by preparing a mixture of polymers and acidic compounds and then forming a membrane by forming a sheet article and then solidifying it

Membrane to be generated.

Suitable polymers include polyolefins such as poly (chloropreri), polyacetylene, polyphenylene, poly (p-xylylene), polyarylmethylene, polystyrene, polymethylstyrene, polyvinyl alcohol, polyvinyl acetate, polyvinyl ether,

Polyvinylamine, poly (N-vinylacetamide), polyvinylimidazole, polyvinylcarbazole, polyvinylpyrrolidone, polyvinylpyridine, polyvinylchloride, polyvinylidene chloride, polytetrafluoroethylene (PTFE), polyhexafluoropropylene, copolymers of PTFE with hexafluoropropylene, with perfluoropropyl vinyl ether, with trifluoronitrosomethane, with carbalkoxy perfluoroalkoxy vinyl ether, polychlorotrifluoroethylene, polyvinyl fluoride,

Polyvinylidene fluoride, polyacrolein, polyacrylamide, polyacrylonitrile, polycyanoacrylates, polymethacrylimide, cycloolefinic copolymers, in particular of norbornene; Polymers having CO bonds in the main chain, for example polyacetal, polyoxymethylene, polyether, polypropylene oxide, polyepichlorohydrin, polytetrahydrofuran, polyphenylene oxide, polyether ketone, polyesters, in particular polyhydroxyacetic acid, polyethylene terephthalate, polybutylene terephthalate,

Polyhydroxybenzoate, polyhydroxypropionic acid, polypivalolactone, polycaprolactone, polymalonic acid, polycarbonate;

Polymers having C-S bonds in the main chain, for example, polysulfide ethers, polyphenylene sulfide, polysulfones, polyethersulfone;

Polymers having C-N bonds in the main chain, for example polyimines, polyisocyanides, polyetherimine, polyetherimides, polyaniline, polyaramides, polyamides, polyhydrazides, polyurethanes, polyimides, polyazoles, polyazole ether ketone, polyazines;

liquid crystalline polymers, especially Vectra ™ as well as

inorganic polymers, for example polysilanes, polycarbosilanes, polysiloxanes, polysilicic acid, polysilicates, silicones, polyphosphazenes and polythiazyl.

Here, basic polymers are preferred, and this applies in particular to membranes which are doped with acids. As acid-doped basic polymer membrane almost all known polymer membranes are suitable, in which the protons can be transported. In this case, acids are preferred which release protons without additional water, e.g. by means of the so-called Grotthus mechanism.

As the basic polymer in the context of the present invention is preferably a basic polymer having at least one nitrogen, oxygen or sulfur atom, preferably at least one nitrogen atom, in one

Repeat unit used. Furthermore, basic polymers comprising at least one heteroaryl group are preferred.

The repeating unit in the basic polymer according to a preferred embodiment contains an aromatic ring having at least one nitrogen atom. The aromatic ring is preferably a five- or six-membered ring having one to three nitrogen atoms which may be fused to another ring, especially another aromatic ring.

According to a particular aspect of the present invention, ^* high-temperature-stable polymers are used which contain at least one nitrogen, Oxygen and / or sulfur atom contained in one or in different repeat units.

High temperature stability in the context of the present invention is a polymer which can be operated as a polymeric electrolyte in a fuel cell at temperatures above 120 ⁰ C permanently. Permanently means that a membrane of the invention for at least 100 hours, preferably at least 500 hours, at least 80 ° C, preferably at least 120 ° C, more preferably at least 160 ° C, can be operated without the power, according to the in WO 01 / 18894 A2 method can be measured to more than

50%, based on the initial performance, decreases.

In the context of the present invention, all the abovementioned polymers can be used individually or as a mixture (blend). Blends which contain polyazoles and / or polysulfones are particularly preferred. The preferred ones

Blend components are polyethersulfone, polyether ketone and modified with sulfonic acid polymers, as described in German Patent Application DE 100 522 42 and DE 102 464 61. The use of blends can improve mechanical properties and reduce material costs.

Furthermore, polymer blends which comprise at least one basic polymer and at least one acidic polymer, preferably in a weight ratio of from 1:99 to 99: 1 (so-called acid-base polymer blends), have proven especially useful for the purposes of the present invention. Particularly suitable acidic polymers in this context include polymers having sulfonic acid and / or phosphonic acid groups. Very particularly suitable acid-base polymer blends according to the invention are described in detail, for example, in the publication EP1073690 A1.

A particularly preferred group of basic polymers are polyazoles. A basic polymer based on polyazole contains recurring azole units of the general formula (I) and / or (II) and / or (III) and / or (IV) and / or (V ) and / or (VI) and / or (VII) and / or (VIII) and / or (IX) and / or (X) and / or (Xl) and / or (XII) and / or (XIII) and / or (XIV) and / or (XV) and / or (XVI) and / or

(XVI) and / or (XVII) and / or (XVIII) and / or (XIX) and / or (XX) and / or (XXI) and / or (XXII)

wherein

Ar are the same or different and represent a four-membered aromatic or heteroaromatic group, which may be mono- or polynuclear,

Ar ^{1 are the} same or different and represent a divalent aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{2 may be} identical or different and represent a two- or three-membered aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{3 are the} same or different and are a trivalent aromatic or heteroaromatic group which may be mono- or polysubstituted, Ar ^{4 are} identical or different and represent a trivalent aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{5 are the} same or different and are a four-membered aromatic or heteroaromatic group which may be mono- or polysubstituted, Ar ^{6 are} identical or different and represent a divalent aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ⁷ are the same or different and are a divalent aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{8 are the} same or different and are a trivalent aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{9 is the} same or are different and are a bi- or tri- or vierbindige aromatic or heteroaromatic group which may be mononuclear or polynuclear, Ar ^{10 are the} same or different and represent a di- or trivalent aromatic or heteroaromatic group, the mononuclear or polynuclear Ar ^{11 may be the} same or different and is for a dodecahedral aromatic or heteroaromati group, which can be mononuclear or polynuclear,

X is the same or different and is oxygen, sulfur or a

Amino group which represents a hydrogen atom, a 1-20 carbon atoms group, preferably a branched or unbranched

Alkyl or alkoxy group, or an aryl group as a further radical R in all formulas other than formula (XX) is identical or different to hydrogen, an alkyl group or an aromatic group and in formula (XX) for a

Alkylene group or an aromatic group and n, m is an integer greater than or equal to 10, preferably greater than or equal to 100.

Preferred aromatic or heteroaromatic groups are derived from benzene,

Naphthalene, biphenyl, diphenyl ether, diphenylmethane, diphenyldimethylmethane, bisphenone, diphenylsulfone, quinoline, pyridine, bipyridine, pyridazine, pyrimidine, pyrazine, triazine, tetrazine, pyrol, pyrazole, anthracene, benzopyrrole, benzotriazole, benzooxathiadiazole, benzooxadiazole, benzopyridine, benzopyrazine, benzopyrazidine, Benzopyrimidine, benzopyrazine, benzotriazine, indolizine, quinolizine, pyridopyridine,

Imidazopyrimidine, pyrazinopyrimidine, carbazole, aciridine, phenazine, benzoquinoline, phenoxazine, phenothiazine, acridizine, benzopteridine, phenanthroline and phenanthrene, which may optionally also be substituted.

Here, the substitution pattern of Ar ¹ , Ar ⁴ , Ar ⁶ , Ar ⁷ , Ar ⁸ , Ar ⁹ , Ar ¹⁰ , Ar ^{11 is} arbitrary, in

For example, in the case of phenylene, Ar ¹ , Ar ⁴ , Ar ⁶ , Ar ⁷ , Ar ⁸ , Ar ⁹ , Ar ¹⁰ , Ar ^{11 may be} ortho, meta and para-phenylene. Particularly preferred groups are derived from benzene and biphenylene, which may optionally also be substituted.

Preferred alkyl groups are short chain alkyl groups of 1 to 4

Carbon atoms, such as. For example, methyl, ethyl, n- or i-propyl and t-butyl groups. Preferred aromatic groups are phenyl or naphthyl groups. The alkyl groups and the aromatic groups may be substituted.

Preferred substituents are halogen atoms such as. For example, fluorine, amino groups, hydroxy groups or short-chain alkyl groups, such as. For example, methyl or ethyl groups.

Preference is given to polyazoles having repeating units of the formula (I) in which the radicals X within a repeating unit are identical.

The polyazoles can in principle also have different recurring

Have units that differ, for example, in their remainder X. Preferably, however, it has only the same X radicals in a repeating unit.

Further preferred polyazole polymers are polyimidazoles, polybenzothiazoles,

Polybenzoxazoles, polyoxadiazoles, polyquinoxalines, polythiadiazoles, poly (pyridines), poly (pyrimidines) and poly (tetrazapyrenes).

In a further embodiment of the present invention, the polymer containing recurring azole units is a copolymer or a blend containing at least two units of the formulas (I) to (XXI) which differ from each other. The polymers can be present as block copolymers (diblock, triblock), random copolymers, periodic copolymers and / or alternating polymers.

In a ^{'particularly} preferred embodiment of the present invention, the polymer comprising recurring azole units is a polyazole containing only units of the formula (I) and / or (II).

The number of repeating azole units in the polymer is preferably an integer greater than or equal to 10. Particularly preferred polymers contain at least 100 recurring azole units.

In the context of the present invention, polymers containing recurring benzimidazole units are preferred. Some examples of the extremely expedient

Polymers containing recurring benzimidazole units are represented by the following formulas:

10

where n and m are integers greater than or equal to 10, preferably greater than or equal to 100.

The polyazoles used, but especially the polybenzimidazoles are characterized by a high molecular weight. Measured as intrinsic viscosity, this is at least 0.2 dl / g, preferably 0.8 to 10 dl / g, in particular 1 to 10 dl / g.

The preparation of such polyazoles is known, wherein one or more aromatic tetra-amino compounds having one or more aromatic

Carboxylic acids or their esters containing at least two acid groups per carboxylic acid monomer are reacted in the melt to form a prepolymer. The resulting prepolymer solidifies in the reactor and is then mechanically comminuted. The powdery prepolymer is customarily polymerized in a solid state polymerization at temperatures of up to 400 ° C.

Among the preferred aromatic carboxylic acids include di-carboxylic acids and tri-carboxylic acids and tetra-carboxylic acids or their esters or their anhydrides or their acid chlorides. The term aromatic carboxylic acids equally includes heteroaromatic carboxylic acids.

Preferably, the aromatic dicarboxylic acids are isophthalic acid, terephthalic acid, phthalic acid, 5-hydroxyisophthalic acid, 4-hydroxyisophthalic acid, 2-hydroxyterephthalic acid, 5-aminoisophthalic acid, 5-N ₁ N- Dimethylaminoisophthalic acid, 5-N, N-diethylaminoisophthalic acid, 2,5-dihydroxyterephthalic acid, 2,6-dihydroxyisophthalic acid, 4,6-dihydroxyisophthalic acid, 2,3-dihydroxyphthalic acid, 2,4-dihydroxyphthalic acid, 3,4-dihydroxyphthalic acid, 3-fluorophthalic acid, 5-fluoroisophthalic acid, 2-fluoroterephthalic acid, tetrafluorophthalic acid, tetrafluoroisophthalic acid,

Tetrafluoroterephthalic acid, 1,4-naphtha! Indicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, diphenic acid, 1,8-dihydroxynaphthalene-3,6-dicarboxylic acid, diphenyl ether-4,4'-dicarboxylic acid , Benzophenone-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, biphenyl-4,4'-dicarboxylic acid, 4-trifluoromethylphthalic acid, 2,2-

Bis- (4-carboxyphenyl) -hexafluoropropane, 4,4'-stilbenedicarboxylic acid, 4-carboxycinnamic acid, or their C1-C20-alkyl esters or C5-C12-aryl esters, or their acid anhydrides or their acid chlorides.

The aromatic tri-, tetra-carboxylic acids or their C1-C20-alkyl esters or C5-C12-aryl esters or their acid anhydrides or their acid chlorides are preferably 1,3,5-benzenetricarboxylic acid (trimesic acid ), 1, 2,4-benzenetricarboxylic acid (trimellitic acid), (2-carboxyphenyl) -iminodiacetic acid, 3,5,3'-biphenyltricarboxylic acid or 3,5,4'-biphenyltricarboxylic acid.

The aromatic tetracarboxylic acids or their C 1 -C 20 -alkyl esters or C 5 -C 12 -aryl esters or their acid anhydrides or their acid chlorides are preferably 3,5,3 ', 5'-biphenyltetracarboxylic acid, 1, 2,4 , 5-benzotetracarboxylic acid, benzophenone tetracarboxylic acid, 3,3 ', 4,4'-biphenyltetracarboxylic acid, 2,2', 3,3'-biphenyltetracarboxylic acid, 1, 2,5,6-naphthalenetetracarboxylic acid or 1, 4,5,8-

Naphthalene.

The heteroaromatic carboxylic acids used are preferably heteroaromatic dicarboxylic acids or tricarboxylic acids or tetracarboxylic acids or their esters or their anhydrides. As heteroaromatic

Carboxylic acids are understood to be aromatic systems which contain at least one nitrogen, oxygen, sulfur or phosphorus atom in the aromatic. Preferably pyridine-2,5-dicarboxylic acid, pyridine-3,5-dicarboxylic acid, pyridine-2,6-dicarboxylic acid, pyridine-2,4-dicarboxylic acid, 4-phenyl-2,5-pyridinedicarboxylic acid, 3,5 -Pyrazoldicarboxylic acid, 2,6-pyrimidinedicarboxylic acid, 2,5-

Pyrazine dicarboxylic acid, 2,4,6-pyridine tricarboxylic acid or benzimidazole-5,6-dicarboxylic acid or their C1-C20 alkyl esters or C5-C12 aryl esters, or their acid anhydrides or their acid chlorides.

The content of tricarboxylic acid or tetracarboxylic acids (based on used

Dicarboxylic acid) is between 0 and 30 mol%, preferably 0.1 and 20 mol%, in particular 0.5 and 10 mol%. The aromatic and heteroaromatic diaminocarboxylic acids used are preferably diaminobenzoic acid or its mono- and dihydrochloride derivatives.

Preference is given to using mixtures of at least 2 different aromatic carboxylic acids. Particular preference is given to using mixtures which, in addition to aromatic carboxylic acids, also contain heteroaromatic carboxylic acids. The mixing ratio of aromatic carboxylic acids to heteroaromatic carboxylic acids is between 1:99 and 99: 1, preferably

1: 50 to 50: 1.

These mixtures are in particular mixtures of N-heteroaromatic di-carboxylic acids and aromatic dicarboxylic acids. Non-limiting examples are isophthalic acid, terephthalic acid, phthalic acid, 2,5-

Dihydroxyterephthalic acid, 2,6-dihydroxyisophthalic acid, 4,6-dihydroxyisophthalic acid, 2,3-dihydroxyphthalic acid, 2,4-dihydroxyphthalic acid. 3,4-dihydroxyphthalic acid, 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, diphenic acid, 1,8-dihydroxynaphthalene-3,6-dicarboxylic acid, diphenyl ether-4,4 ' -dicarbohsäure,

Benzophenone-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid, biphenyl-4,4'-dicarboxylic acid, 4-trifluoromethylphthalic acid, pyridine-2,5-dicarboxylic acid, pyridine-3,5-dicarboxylic acid, pyridine-2 , 6-dicarboxylic acid, pyridine-2,4-dicarboxylic acid, 4-phenyl-2,5-pyridinedicarboxylic acid, 3,5-pyrazoldicarboxylic acid, 2,6-pyrimidinedicarboxylic acid, 2,5-pyrazinedicarboxylic acid.

Among the preferred aromatic tetra-amino compounds include 3,3 ', 4,4'-tetraaminobiphenyl, 2,3,5,6-tetraaminopyridine, 1, 2,4,5-tetraaminobenzene, 3,3', 4 , 4'-tetraaminodiphenylsulfone, 3,3 ', 4,4'-tetraaminodiphenyl ether, 3,3', 4,4'-tetraaminobenzophenone, 3,3 ', 4,4'-

Tetraaminodiphenylmethane and 3,3 ', 4,4'-tetraaminodiphenyldimethylmethane and salts thereof, in particular their mono-, di-, tri- and tetrahydrochloride derivatives.

Preferred polybenzimidazoles are commercially available under the trade name © Celazole from Celanese AG.

Preferred polymers include polysulfones, especially polysulfone having aromatic and / or heteroaromatic groups in the backbone. Have According to a particular aspect of the present invention, preferred polysulfones and polyether sulfones have a melt volume rate MVR 300/21, 6 is less than or equal to 40 cm ^3/10 min, especially less than or equal to 30 cm ^3/10 min and particularly preferably less than or equal to 20 cm ³ / 10 minutes measured according to ISO 1 133 on. Here are polysulfones having a Vicat softening temperature VST / A / 50 of 180 ⁰ C to 230 ⁰ C are preferred. In still a preferred embodiment of the present invention, the number average molecular weight of the polysulfones is greater than 30,000 g / mol.

The polymers based on polysulfone include, in particular, polymers which contain repeating units having linking sulfone groups corresponding to the general formulas A, B, C, D, E ₁ F and / or G:

wherein the radicals R, independently of one another or different, represent an aromatic or heteroaromatic group, these radicals having been explained in more detail above. These include in particular 1, 2-phenylene, 1, 3-PhenyIen, 1, 4-phenylene, 4,4'-biphenyl, pyridine, quinoline, naphthalene, phenanthrene.

Preferred polysulfones for the purposes of the present invention include homopolymers and copolymers, for example random copolymers. Particularly preferred polysulfones comprise recurring units of the formulas H to N:

with n> o with n <o

The polysulfones described above may under the trade names ^® Victrex 200 P, ^® Victrex 720 P, ^® Ultrason E, ^® Ultrason S ₁ ^® Mindel, ^® Radel A ₁ ^® Radel R ₁ ^® Victrex HTA, ^® Astrel and ^® Udel be obtained commercially.

In addition, polyether ketones, polyether ketone ketones, polyether ether ketones, polyether ether ketone ketones and polyaryl ketones are particularly preferred. These high performance polymers are known per se and can be obtained commercially under the trade names Victrex® PEEK ™, ^® Hostatec, ^® Kadel.

For the production of polymer films, a polymer, preferably a polyazole, can be dissolved in a further step in polar, aprotic solvents, such as, for example, dimethylacetamide (DMAc), and a film produced by means of classical processes.

To remove residual solvent, the film thus obtained can be treated with a washing liquid as described in German patent application DE 101 098 29. The cleaning of the polyazole film from solvent residues described in the German patent application surprisingly improves the mechanical properties of the film. These properties include in particular the modulus of elasticity, the tear strength and the fracture toughness of the film.

In addition, the polymer film can be further modified, for example by crosslinking, as described in German Patent Application DE 101 107 52 or in WO 00/44816 described. In a preferred embodiment, the polymer film used comprising a basic polymer and at least one blend component additionally contains a crosslinker, as described in German patent application DE 101 401 47.

The thickness of the Polyazolfolien can be within a wide range. Preferably, the thickness of the Polyazolfolie prior to doping with acid in the range of 5 microns to 2000 microns, more preferably in the range of 10 .mu.m to 1000 .mu.m, without this being a limitation.

To achieve proton conductivity, these films are doped with an acid. Acids in this context include all known Lewis and Brønsted acids, preferably Lewis and Bransted inorganic acids.

Furthermore, the use of polyacids is possible, in particular isopolyacids and heteropolyacids and mixtures of various acids. For the purposes of the present invention, heteropolyacids mean inorganic polyacids having at least two different central atoms, which are each composed of weak, polybasic oxygen acids of a metal (preferably Cr, Mo, V, VV) and of a nonmetal (preferably As, I, P, Se, Si, Te) as partial mixed anhydrides. These include, among others, 12-molybdophosphoric acid and 12-tungstophosphoric acid.

About the degree of doping, the conductivity of the Polyazolfolie can be influenced. The conductivity increases with increasing concentration of dopant until a maximum value is reached.

According to the invention, the degree of doping is given as mol of acid per mole of repeat unit of the polymer. In the context of the present invention, a degree of doping between 3 and 80, advantageously between 5 and 60, in particular between 12 and 60, is preferred.

Particularly preferred dopants are sulfuric acid and phosphoric acid, or compounds which release these acids, for example upon hydrolysis. A most preferred dopant is phosphoric acid (HaPO ₄ ). Here, highly concentrated acids are generally used. According to a particular aspect of the present invention, the concentration of the phosphoric acid is at least 50% by weight, in particular at least 80% by weight, based on the weight of the doping agent.

Furthermore, proton-conductive membranes can also be obtained by a process comprising the steps of I) dissolving polymers, in particular polyazoles in polyphosphoric acid, II) heating the solution obtainable according to step I) under inert gas to temperatures of up to 40O ⁰ C,

III) forming a membrane using the solution of the polymer according to step II) on a support and IV) treating the membrane formed in step III) until it is self-supporting.

Further details of such proton-conducting membranes can be found, for example, in DE 102 464 61. They are available, for example under the trade name Celtec ^®.

Furthermore, doped polyazole films can be obtained by a process comprising the steps

A) mixing one or more aromatic tetra-amino compounds with one or more aromatic carboxylic acids or their esters containing at least two acid groups per carboxylic acid monomer, or

Mixing one or more aromatic and / or heteroaromatic diaminocarboxylic acids in polyphosphoric acid to form a solution and / or dispersion

B) applying a layer using the mixture according to step A) on a carrier or on an electrode,

C) heating of the sheet / layer obtainable according to step B) under inert gas to temperatures of up to 350 ⁰ C, preferably up to 280 ⁰ C to form the polyazole polymer.

D) treatment of the membrane formed in step C) (until it is self-supporting).

Further details of such proton-conducting membranes can be found, for example, in DE 10246459. They are available, for example under the trade name Celtec ^®.

The in step A) to be used aromatic or heteroaromatic

Carboxylic and tetra-amino compounds have been previously described.

The polyphosphoric acid used in step A) are commercially available polyphosphoric acids, as are obtainable, for example, from Riedel-de Haen. The polyphosphoric acids H _{n + 2} PnO _{3n +} i (n> 1) usually have a content calculated as P ₂ O ₅ (acidimetric) of at least 83%. Instead of a solution of the monomers, it is also possible to produce a dispersion / suspension.

The mixture produced in step A) has a weight ratio of polyphosphoric acid to sum of all monomers of 1: 10,000 to 10,000: 1, preferably 1: 1000 to

1000: 1, in particular 1: 100 to 100: 1, on. The layer formation according to step B) takes place by means of measures known per se (casting, spraying, doctoring) which are known from the prior art for polymer film preparation. Suitable carriers are all suitable carriers under the conditions as inert. To adjust the viscosity, the solution may optionally be treated with phosphoric acid (concentrated phosphoric acid, 85%).

This allows the viscosity to be adjusted to the desired value and the formation of the membrane can be facilitated.

The layer produced according to step B) has a thickness between 20 and 4000 μm, preferably between 30 and 3500 μm, in particular between 50 and 3000 μm.

Insofar as the mixture according to step A) also contains tricarboxylic acids or tetracarboxylic acid, this results in a branching / crosslinking of the polymer formed. This contributes to the improvement of the mechanical property.

Treatment of the polymer layer produced according to step C) in the presence of moisture at temperatures and for a sufficient time until the layer has sufficient strength for use in fuel cells. The treatment can be done so far that the membrane is self-supporting, so they without

Damage can be detached from the carrier.

According to step C), the flat structure obtained in step B) is heated to a temperature of up to 35O ⁰ C, preferably up to 280 ⁰ C and particularly preferably in the range of 200 ⁰ C to 250 ⁰ C. The inert gases to be used in step C) are known in the art. These include in particular nitrogen and noble gases, such as neon, argon, helium.

In a variant of the method the mixture of step A) to temperatures of up can be about 350 ° C, preferably up to 280 ⁰ C, already the formation of oligomers and / or polymers effected by heating. Depending on the selected temperature and duration, then the heating in step C) can be omitted partially or completely. This variant is also the subject of the present invention.

The treatment of the membrane in step D) is carried out at temperatures above ^{0 0} C and below 15O ⁰ C, preferably at temperatures between 10 ⁰ C and 12O ⁰ C, in particular between room temperature (2O ⁰ C) and 90 ⁰ C, in the presence of moisture or water and / or water vapor and / or water-containing phosphoric acid of up to 85%. The treatment is preferably carried out under

Normal pressure, but can also be done under the action of pressure. It is essential that the treatment be done in the presence of sufficient moisture, whereby the present polyphosphoric acid by partial hydrolysis to form low molecular weight polyphosphoric acid and / or phosphoric acid contributes to the solidification of the membrane.

The partial hydrolysis of the polyphosphoric acid in step D) leads to a

Solidification of the membrane and a decrease in the layer thickness and formation of a membrane having a thickness between 15 and 3000 .mu.m, preferably between 20 and 2000 .mu.m, in particular between 20 and 1500 .mu.m, which is self-supporting.

The intra- and intermolecular structures (interpenetrating networks IPN) present in the polyphosphoric acid layer according to step B) result in an orderly membrane formation in step C) which is responsible for the particular properties of the membrane formed.

The upper temperature limit of the treatment according to step D) is usually

150 ^° C. With extremely short exposure to moisture, for example superheated steam, this steam may also be hotter than 150 ^° C. Essential for the upper temperature limit is the duration of the treatment.

The partial hydrolysis (step D) can also be carried out in climatic chambers in which the hydrolysis can be controlled in a controlled manner under defined action of moisture. In this case, the moisture can be adjusted in a targeted manner by the temperature or saturation of the contacting environment, for example gases, such as air, nitrogen, carbon dioxide or other suitable gases, or water vapor. The duration of treatment depends on the parameters selected above.

Furthermore, the duration of treatment depends on the thickness of the membrane.

In general, the treatment time is between a few seconds to minutes, for example under the action of superheated steam, or up to full days, for example in air at room temperature and low relative humidity. The treatment time is preferably between 10 seconds and 300 hours, in particular 1 minute to 200 hours.

If the partial hydrolysis is carried out at room temperature (20 ^° C.) with ambient air having a relative atmospheric humidity of 40-80%, the treatment duration is between 1 and 200 hours.

The membrane obtained according to step D) can be made self-supporting, ie it can be detached from the support without damage and then optionally further processed directly. About the degree of hydrolysis, ie the duration, temperature and ambient humidity, the concentration of phosphoric acid and thus the conductivity of the polymer membrane is adjustable. The concentration of phosphoric acid is reported as moles of acid per mole of repeat unit of the polymer. By the method comprising steps A) to D), membranes having a particularly high phosphoric acid concentration can be obtained. A concentration (mol of phosphoric acid relative to a repeat unit of the formula (I), for example polybenzimidazole) is preferably between 10 and 50, in particular between 12 and 40. Such high doping levels (concentrations) are only very high by doping of polyazoles with commercially available ortho-phosphoric acid difficult or not accessible.

According to a modification of the process described, in which doped Polyazolfolien are prepared by the use of polyphosphoric acid, the production of these films can also be carried out by a method comprising the

steps

1) Reaction of one or more aromatic tetra-amino compounds with one or more aromatic carboxylic acids or their esters containing at least two acid groups per carboxylic acid monomer, or of one or more aromatic and / or heteroaromatic diaminocarboxylic acids in the melt at temperatures of up to 350 ^° C., preferably up to 300 ^° C.,

2) dissolving the solid prepolymer obtained in step 1) in polyphosphoric acid, 3) heating the solution obtainable according to step 2) under inert gas

Temperatures of up to 300 ⁰ C, preferably up to 280 ° C, to form the dissolved polyazole polymer,

4) forming a membrane using the solution of the polyazole polymer according to step 3) on a support and 5) treating the membrane formed in step 4) until it is self-supporting.

The method steps described under points 1) to 5) were previously explained in more detail for steps A) to D), reference being made to this, in particular with regard to preferred embodiments.

Further details of such proton-conducting membranes can be found, for example, in DE 102 464 59. They are available, for example under the trade name Celtec ^®.

In a further preferred embodiment of the present invention

Membranes are used which comprise polymers comprising monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups are derived, and which are available, for example, under the trade name Celtec ^® .

These proton-conducting polymer membranes are obtainable, inter alia, by a process described, for example, in DE 102 135 40, comprising the steps

A) Preparation of a mixture comprising monomers comprising phosphonic acid groups and at least one polymer,

B) applying a layer using the mixture according to step A) on a support, C) polymerizing the monomers present in the planar structure obtainable according to step B) phosphonic acid groups.

Furthermore, such proton-conducting polymer membranes are obtainable by a process described, for example, in DE 102 094 19 comprising the steps of: I) swelling a polymer film with a liquid containing phosphonic acid monomers and II) polymerizing at least a portion of the monomers comprising phosphonic acid groups; Step I) were introduced into the polymer film.

Swelling is understood as meaning a weight increase of the film of at least 3% by weight. Preferably, the swelling is at least 5%, more preferably at least 10%.

Determination of Swelling Q is determined gravimetrically from the mass of the film before swelling m ₀ and the mass of the film after the polymerization according to step B), m ₂ .

The swelling is preferably carried out at a temperature above 0 ⁰ C, in particular between room temperature (2O ⁰ C) and 180 ⁰ C in a liquid containing preferably at least 5 wt .-% phosphonic acid monomers. Furthermore, the swelling can also be carried out at elevated pressure. Here are the limits of economic considerations and technical possibilities.

The polymer film used for swelling generally has a thickness in the range from 5 to 3000 .mu.m, preferably from 10 to 1500 .mu.m. The preparation of such films from polymers is generally known, some of which are commercially available. The term polymeric film means that the film to be swollen comprises polymers having aromatic sulfonic acid groups, which film may contain other common additives. The preparation of the films and preferred polymers, in particular polyazoles and / or polysulfones have been described above.

The liquid, the monomers comprising phosphonic acid groups and / or

Containing monomers containing sulfonic acid groups, may be a solution, wherein the liquid also suspended and / or dispersed. May contain ingredients. The viscosity of the liquid containing phosphonic acid monomers can be within a wide range, with the setting of the _. Viscosity an addition of solvents or an increase in temperature can be done. The dynamic viscosity is preferably in the range from 0.1 to 10000 mPa * s, in particular from 0.2 to 2000 mPa * s, where these values can be measured, for example, in accordance with DIN 53015.

Monomers containing phosphonic acid groups and / or monomers comprising sulfonic acid groups are known in the art. These are compounds which have at least one carbon-carbon double bond and at least one phosphonic acid group. Preferably, the two carbon atoms that form the carbon-carbon double bond have at least two, preferably three, bonds to groups that result in little steric hindrance of the double bond. These groups include, among others, hydrogen atoms and halogen atoms, especially fluorine atoms. In the context of the present invention, the polymer comprising phosphonic acid groups results from the polymerization product obtained by polymerization of the monomer comprising phosphonic acid groups alone or with further

Monomer ^" and / or Vernetzerri is obtained.

The monomer comprising phosphonic acid groups may comprise one, two, three or more carbon-carbon double bonds. Furthermore, the monomer comprising phosphonic acid groups may be one, two, three or more

Contain phosphonic acid groups.

In general, the monomer comprising phosphonic acid groups contains 2 to 20, preferably 2 to 10, carbon atoms.

The monomer comprising phosphonic acid groups used to prepare the phosphonic acid groups are preferably compounds of the formula

wherein R represents a bond, a C1-C15 double-alkylene group, a C1-C15 double-alkyleneoxy group, for example an ethyleneoxy group, or a C5-C20 double-aryl or heteroaryl group, the above radicals being in turn denoted by halogen, -OH, COOZ, - CN, NZ ₂ can be substituted,

Z independently of one another hydrogen, C1-C15-alkyl group, C1-C15-

Alkoxy group, ethyleneoxy group or C5-C20-aryl or heteroaryl group, where the above radicals may themselves be substituted by halogen, -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6, 7, 8 , 9 or 10, y is an integer 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 and / or the formula

wherein

R is a bond, a C1-C15 divalent alkylene group, C1-C15 double-alkyleneoxy group, for example an ethyleneoxy group, or a C5-C20 double-aryl or heteroaryl group, the above radicals being in turn denoted by halogen, -OH, COOZ, CN, NZ ₂ can be substituted,

Z is independently of one another hydrogen, C1-C15-alkyl group, C1-C15-alkoxy group, for example an ethyleneoxy group or a C5-C20-aryl or heteroaryl group, the above radicals in turn having

Halogen, -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 means

and / or the formula

wherein

A is a group of the formula COOR ² , CN, CONR ² ₂ , OR ² and / or R ² , R ^{2 is} hydrogen, a C 1 -C 15 alkyl group, C 1 -C 15 alkoxy group, for example an ethyleneoxy group or a C 5 -C 20 aryl or heteroaryl group, where the above radicals in turn with halogen, -OH, COOZ, -

CN, NZ ₂ R may be a bond, a divalent C1-C15 alkylene group, divalent C1-C15

Alkylenoxygruppe, for example, ethyleneoxy group or divalent C5-C20-aryl or heteroaryl group, where the above radicals may in turn be substituted by halogen, -OH, COOZ, -CN, NZ ₂ , Z independently of one another hydrogen, C1-C15-alkyl group, C1-C15-

Alkoxy group, ethyleneoxy group or C5-C20-aryl or heteroaryl group, wherein the above radicals in turn with halogen; -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10.

Among the monomers comprising preferred phosphonic acid groups are, inter alia, alkenes having phosphonic acid groups, such as ethenephosphonic acid, propenephosphonic acid, butenephosphonic acid; Acrylic acid and / or methacrylic acid compounds which have phosphonic acid groups, for example 2-phosphonomethylacrylic acid, 2-phosphonomethylmethacrylic acid, 2-phosphonomethylacrylamide and 2-phosphonomethylmethacrylamide.

Commercially available vinylphosphonic acid (ethenephosphonic acid), such as, for example, from Aldrich or Clariant, is particularly preferred

GmbH is available, used. A preferred vinylphosphonic acid has a purity of more than 70%, in particular 90% and particularly preferably more than 97% purity.

The monomers comprising phosphonic acid groups can furthermore also be mentioned in US Pat

Form of derivatives can be used, which can then be converted into the acid, wherein the transfer to the acid can also take place in the polymerized state. These derivatives include, in particular, the salts, the esters, the amides and the halides of the monomers comprising phosphonic acid groups.

The liquid used preferably comprises at least 20% by weight, in particular at least 30% by weight and particularly preferably at least 50% by weight, based on the total weight of the mixture, of monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups.

The liquid used may additionally contain other organic and / or inorganic solvents. The organic solvents include in particular polar aprotic solvents, such as dimethyl sulfoxide (DMSO), esters, such as ethyl acetate, and polar protic solvents, such as alcohols, such as ethanol, propanol, isopropanol and / or butanol. The inorganic solvent includes, in particular, water, phosphoric acid and polyphosphoric acid.

These can positively influence the processability. In particular, by adding the organic solvent, the receptivity of the film with respect to the monomers can be improved. The content of monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups in such solutions is generally at least 5% by weight, preferably at least 10% by weight, more preferably between 10 and 97% by weight.

Monomers comprising sulfonic acid groups are known in the art. These are compounds which have at least one carbon-carbon double bond and at least one sulfonic acid group. Preferably, the two carbon atoms β forming the carbon-carbon double bond have at least two, preferably 3, bonds to groups that result in little steric hindrance of the double bond. These groups include, among others, hydrogen atoms and halogen atoms, especially fluorine atoms. In the context of the present invention, this results

Sulfonsäuregruppen comprising polymer from the polymerization, which is obtained by polymerization of the monomers comprising sulfonic acid groups alone or with other monomers and / or Vernetzem.

The monomer comprising sulfonic acid groups may be one, two, three or more

Include carbon-carbon double bonds. Further, the monomer comprising sulfonic acid groups may contain one, two, three or more sulfonic acid groups.

In general, the monomer comprising sulfonic acid groups contains 2 to 20, preferably 2 to 10, carbon atoms.

The monomer comprising sulfonic acid groups are preferably compounds of the formula

wherein

R represents a bond, a C1-C15 double-alkylene group, a C1-C15 double-alkyleneoxy group, for example an ethyleneoxy group, or a C5-C20 double-aryl or heteroaryl group, the above radicals being in turn denoted by halogen, -OH, COOZ, - CN, NZ ₂ can be substituted,

Z independently of one another hydrogen, C1-C15-alkyl group, C1-C15-

Alkoxy group, for example an ethyleneoxy group, or a C5-C20-aryl or heteroaryl group, where the above radicals may in turn be substituted by halogen, -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6 , 7, 8, 9 or 10, y is an integer 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 and / or the formula wherein

R represents a bond, a C1-C15 double-bonded alkylene group, a C1-C15 double-alkyleneoxy group, for example an ethyleneoxy group, or a C5-C20 double-aryl or heteroaryl group, where the above radicals are themselves halogen, -OH, COOZ, - CN, NZ ₂ can be substituted, Z independently of one another are hydrogen, C 1 -C 15 -alkyl group, C 1 -C 15-

Alkoxy group, for example an ethyleneoxy group, or a C5-C20-aryl or heteroaryl group, where the above radicals may in turn be substituted by halogen, -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6 , 7, 8, 9 or 10 and / or the formula

wherein A represents a group of the formulas COOR ² , CN, CONR ² ₂ , OR ² and / or R ² ,

R ^{2 is} hydrogen, a C 1 -C 15 -alkyl group, C 1 -C -alkoxy group, for example an ethyleneoxy group, or a C 5 -C 20 -aryl or heteroaryl group, where the above radicals are in turn linked to halogen, -OH, COOZ, - CN, NZ ₂ can be substituted R a bond, a divalent C1-C15 alkylene group, divalent C1-C15

Alkyleneoxy group, for example an ethyleneoxy group, or a divalent C5-C20-aryl or heteroaryl group, where the above radicals in turn may be substituted by halogen, -OH, COOZ, -CN, NZ ₂ , Z are independently hydrogen, C1-C15- Alkyl group, C1-C15-

Alkoxy group, for example an ethyleneoxy group, or a C5-C20-aryl or heteroaryl group, where the above radicals may in turn be substituted by halogen, -OH, -CN, and x is an integer 1, 2, 3, 4, 5, 6 , 7, 8, 9 or 10 means.

Included among the preferred monomers comprising sulfonic acid include alkenes having sulfonic acid groups, such as ethene sulfonic acid, propylene sulfonic acid, butene sulfonic acid; Acrylic acid and / or methacrylic acid compounds which have sulfonic acid groups, for example 2-sulfonomethylacrylic acid, 2-sulfonomethylmethacrylic acid, 2-sulfonomethylacrylamide and 2-sulfonomethylmethacrylamide. Commercially available vinyl sulfonic acid (ethene sulfonic acid), as obtainable, for example, from Aldrich or Clariant GmbH, is particularly preferably used. A preferred vinylsulfonic acid has a purity of more than 70%, in particular 90% and particularly preferably more than 97% purity.

The monomers comprising sulfonic acid groups can furthermore also be used in the form of derivatives which can subsequently be converted into the acid, wherein the conversion to the acid can also take place in the polymerized state. These derivatives include, in particular, the salts, the esters, the amides and the halides of the monomers comprising sulfonic acid groups.

According to a particular aspect of the present invention, the weight ratio of monomers comprising sulfonic acid groups to monomers comprising phosphonic acid groups can be in the range from 100: 1 to 1: 100, preferably 10: 1 to 1:10 and more preferably 2: 1 to 1: 2.

According to another particular aspect of the present invention, the monomers comprising phosphonic acid groups are preferred over the monomers comprising sulfonic acid groups. Accordingly, it is particularly preferable to use a liquid having monomers comprising phosphonic acid groups.

In a further embodiment of the invention, monomers which are capable of crosslinking in the preparation of the polymer membrane can be used. These monomers can be added to the liquid used to treat the film. In addition, the monomers capable of crosslinking can also be applied to the sheet after treatment with the liquid.

The monomers capable of crosslinking are in particular compounds which have at least 2 carbon-carbon double bonds. Preference is given to dienes, trienes, tetraenes, dimethyl acrylates,

Trimethyl acrylates, tetramethyl acrylates, diacrylates, triacrylates, tetraacrylates.

Particularly preferred are dienes, trienes, tetraenes of the formula

Dimethyl acrylates, trimethyl acrylates, tetramethyl acrylates of the formula

Diacrylatθ, triacrylates, tetraacrylates of the formula

wherein R is a C 1 -C 15 -alkyl group, C 5 -C 20 -aryl or heteroaryl group, NR ^' , -SO ₂ , PR', Si (R ') ₂ , where the above radicals may themselves be substituted,

R 'independently of one another is hydrogen, a C 1 -C 15 -alkyl group, C 1 -C 15 -alkoxy group, C 5 -C 20 -aryl or heteroaryl group and is at least 2.

The substituents of the above radical R are preferably halogen, hydroxyl, carboxyl, carboxyl, carboxyl ester, nitrile, amine, silyl, siloxane radicals.

Particularly preferred crosslinkers are allyl methacrylate, ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, Triethylenglykoldirnethacrylat, tetra- and polyethylene glycol dimethacrylate, 1, 3 _^ butanediol dimethacrylate, glycerol dimethacrylate, diurethane dimethacrylate, trimethylolpropane trimethacrylate, epoxy acrylates, for example Ebacryl, N ', N-methylenebisacrylamide, carbinol, butadiene, isoprene, chloroprene, divinylbenzene and / or bisphenol A dimethylacryate. These compounds are commercially available, for example, from Sartomer Company Exton, Pennsylvania under the names CN-120, CN104 and CN-980.

The use of crosslinkers is optional, these compounds usually in the range between 0.05 to 30 wt .-%, preferably 0.1 to 20 wt .-%, particularly preferably 1 and 10 wt .-%, based on the weight of Phosphonic acid groups comprising monomers can be used.

The liquid containing monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups may be a solution, the liquid also containing suspended and / or dispersed constituents can. The viscosity of the liquid containing monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups can be within wide limits, it being possible for the viscosity to be adjusted by adding solvents or increasing the temperature. The dynamic viscosity is preferably in the range from 0.1 to 10000 mPa * s, in particular from 0.2 to

2000 mPa * s, whereby these values can be measured according to DIN 53015, for example.

A membrane, in particular eiηe membrane based on polyazoles, can still be crosslinked by the action of heat in the presence of atmospheric oxygen on the surface. This hardening of the membrane surface additionally improves the properties of the membrane. For this purpose, the membrane to a temperature of at least 150 ⁰ C, preferably at least 200 ° C and particularly preferably at least 250 ⁰ C are heated. The oxygen concentration in this process step is usually in the range of 5 to 50% by volume, preferably 10 to 40% by volume, without this being intended to limit it.

The crosslinking can also be effected by the action of IR or NIR (IR = infra red, ie light with a wavelength of more than 700 nm; NIR = near IR, ie light with a wavelength in the range of about 700 to 2000 nm or an energy in the range of about 0.6 to 1.75 eV). Another method is the irradiation with ß-rays. The radiation dose is between 5 and 200 kGy.

Depending on the desired degree of crosslinking, the duration of the crosslinking reaction can be in a wide range. In general, this reaction time is in the range of 1 second to 10 hours, preferably 1 minute to 1 hour, without this being a restriction.

According to the invention, the membrane-electrode assembly comprises at least two electrochemically active electrodes (anode and cathode) which are separated by the polymer electrolyte membrane. The term "electrochemically active" indicates that the electrodes are capable of catalyzing the oxidation of hydrogen and / or at least one refrainate and the reduction of oxygen, this property being obtained by coating the electrodes with platinum and / or ruthenium The term "electrode" means that the material is electrically conductive. The electrode may optionally have a noble metal layer. Such electrodes are known and are described for example in US 4,191,618, US 4,212,714. and US 4,333,805.

The electrodes preferably include gas diffusion layers in contact with a catalyst layer. θ4

As gas diffusion layers usually planar, electrically conductive and säu reresistente structures are used. These include, for example, graphite fiber papers, carbon fiber papers, graphite fabrics and / or papers rendered conductive by the addition of carbon black. Through these layers, a fine distribution of the gas and / or liquid streams is achieved.

Furthermore, gas diffusion layers can be used which contain a mechanically stable support material, which with at least one electrically conductive material, for. As carbon (for example carbon black) is impregnated. For this

Particularly suitable support materials include fibers, for example in the form of nonwovens, papers or fabrics, in particular carbon fibers, glass fibers or fibers containing organic polymers, for example polypropylene, polyester (polyethylene terephthalate), Polyphenylehsulfid or polyether ketones. Further details of such diffusion layers can be found, for example, in WO

9720358 are taken.

The gas diffusion layers preferably have a thickness in the range from 80 μm to 2000 μm, in particular in the range from 100 μm to 1000 μm and particularly preferably in the range from 150 μm to 500 μm.

Furthermore, the gas diffusion layers favorably have a high porosity. This is preferably in the range of 20% to 80%.

The gas diffusion layers may contain conventional additives. These include, but are not limited to, fluoropolymers, e.g. Polytetrafluoroethylene (PTFE) and surface-active substances.

According to a particular embodiment, at least one of the gas diffusion layers may consist of a compressible material. In the context of the present invention, a compressible material is characterized by the property that the gas diffusion layer can be pressed without loss of its integrity by pressure on half, in particular to one third of its original thickness.

This property generally includes gas diffusion layers of graphite fabric and / or paper rendered conductive by the addition of carbon black.

The catalytically active layer contains a _. catalytically active substance. These include precious metals, in particular platinum, palladium, rhodium, iridium and / or ruthenium. These substances can also be in the form of Alloys are used with each other. Furthermore, these substances may also be used in alloys with base metals such as Cr, Zr, Ni, Co and / or Ti. In addition, it is also possible to use the oxides of the abovementioned noble metals and / or base metals. Usually, the above metals are by known methods on a

Support material, usually carbon with a high specific surface area, used in the form of nanoparticles.

According to a particular aspect of the present invention, the catalytically active compounds, i. H. the catalysts, used in the form of particles, which preferably have a size in the range of 1 to 1000 nm, in particular 5 to 200 nm and preferably 10 to 100 nm.

According to a particular embodiment of the present invention, the weight ratio of fluoropolymer to catalyst material comprising at least one noble metal and optionally one or more support materials, greater than 0.1, wherein this ratio is preferably in the range of 0.2 to 0.6.

According to a particular embodiment of the present invention, the catalyst layer has a thickness in the range of 1 to 1000 .mu.m, in particular from 5 to

500 microns, preferably from 10 to 300 microns, on. This value represents an average value that can be determined by measuring the layer thickness in the cross-section of images that can be obtained with a scanning electron microscope (SEM).

According to a particular embodiment of the present invention, the noble metal content of the catalyst layer is 0.1 to 10.0 mg / cm ² , preferably 0.3 to 6.0 _. mg / cm ² and more preferably 0.3 to 3.0 mg / cm ² . These values can be determined by elemental analysis of a flat sample. ,

^'The catalyst layer is generally not self-supporting, but is usually applied to the gas diffusion layer and / or the membrane. In this case, part of the catalyst layer can diffuse, for example, into the gas diffusion layer and / or the membrane, whereby transition layers form. This can also lead to the fact that the catalyst layer can be regarded as part of the gas diffusion layer.

According to the invention, the surfaces of the polymer electrolyte membrane are in contact with the electrodes such that the first electrode is the front side of the polymer electrolyte membrane and the second electrode is the rear side of the polymer electrolyte membrane.

Membrane partially or completely, preferably only partially, covered. Here, the front and the back of the polymer electrolyte membrane OD

the side facing away from the viewer or the polymer electrolyte membrane, wherein a viewing from the first electrode (front), - preferably the cathode, in the direction of the second electrode (back), preferably the anode, takes place.

Conveniently, the polymer electrolyte membrane comprises an inner and an outer region, wherein only the front and the back of the inner region of the polymer electrolyte membrane are in contact with the electrodes. According to this embodiment, the first electrode at least partially covers the front of the inner region of the polymer electrolyte membrane and the second

Electrode at least partially covers the back of the inner region of the polymer electrolyte membrane, if viewed perpendicular to the surface of the polymer electrolyte membrane. The outer region, on the other hand, is not covered by the electrodes if viewed perpendicular to the surface of the polymer electrolyte membrane.

For further information about membrane electrode units, reference is made to the specialist literature, in particular to the patent applications WO 01/18894 A2, DE 195 09 748, DE 195 09 749, WO 00/26982, WO 92/15121 and DE 197 57 492. The disclosure contained in the abovementioned references with regard to the construction and production of membrane-electrode assemblies, as well as the electrodes to be selected, gas diffusion layers and catalysts is also part of the description.

According to the present invention, the membrane-electrode assembly comprises

Sealant on the front and back of the polymer electrolyte membrane. If necessary, the sealing material may partially cover the electrodes. Conveniently, however, this is not the case and the sealing material is located on not covered by the electrodes surfaces of the front and the back of the polymer electrolyte membrane.

Sealing materials suitable for the purposes of the present invention are known to those skilled in the art. They include in particular those materials which have a continuous use temperature of at least 190 ⁰ C, preferably at least 220 ⁰ C and more preferably at least 25O ⁰ C, measured according to MIL-P-46112B,

Paragraph 4.4.4.

According to a particular aspect of the present. Invention sealants are used, which can be applied by thermoplastic methods, preferably injection molding. Therefore, preferably fusible polymers are used as sealing materials. Particularly preferred meltable polymers include fluoropolymers, especially Poly (tetrafluoroethylene-co-hexafluoropropylene) FEP, polyvinylidene fluoride PVDF, perfluoroalkoxy polymer PFA, poly (tetrafluoroethylene-co-perfluoro (methylvinylether)) MFA, vinylidene fluoride (VF2) / hexafluoropropylene (HFP), terpolymers of vinylidene fluoride (VF2) / hexafluoropropylene ( HFP) / tetrafluoroethylene (TFE), copolymers of tetrafluoroethylene (TFE) / propylene (PP) and

Ethylene (E) / tetrafluoroethylene (TFE) / polyperfluoro (methyl vinyl ether) (PMVE), polyketones, polyether ketones (PEK), polyether ether ketones (PEEK), polyether ether ketone ketones (PEEKK), polyethersulfones (PES), polysulfones (PSU), polyphenylene sulfones (PPSU), Polyphenylene sulfides (PPS), polyphenylene oxides (PPO), liquid crystalline polymers (LCP), polyimides (PI), polyetherimides (PEI),

Polyamide-imides (PAI), polyphenylene-quinoxalines. These polymers are widely available commercially for example under the trade names Hostafon ^®, Hyflon ^®, Teflon ^®, Dyneon ^®, Nowoflon ^®, Viton ^®, Kadel ^®, LITE ^® K. Arlon ^®, Gatone ^®, Vitrex ^®, Imidex ^®, Vespel ^®, Fortron ^® , Ryton ^® , Tecetron ^® , Xydar ^® , Gafone ^® , Tecason ^® and Ketron ^® .

Fluoropolymers are most preferred in the context of the present invention as sealing materials.

According to the present invention, the polymer electrolyte membrane has one or more recesses, wherein the sealing material on the front side of the polymer electrolyte membrane with the sealing material on the back of the polymer electrolyte membrane, preferably by the at least one recess in Contact stands.

Conveniently, the polymer electrolyte membrane comprises one or more recesses partially or completely filled with sealing material, the sealing material in the at least one recess, the sealing material on the front side of the polymer electrolyte membrane with the sealing material on the back of the polymer electrolyte. Membrane, preferably in one piece, connects. The term "integral" in this context means that the entire sealing material is connected to each other and therefore represents only a single seal, which, if any, can only be removed completely without destroying the seal.

Shape and size and number of recesses can be chosen arbitrarily in principle. The shape of the recesses can be, for example, semicircular, round, oval, angular, star-shaped. Furthermore, the polymer electrolyte membrane, for example, many, relatively small recesses or a few, comparatively large recesses. However, it has proved to be favorable that the at least one recess is formed as a channel, which is preferably perpendicular to the surface of the polymer electrolyte membrane, d. H. in the viewing direction, if the viewing from the first electrode (front), preferably the cathode, takes place in the direction of the second electrode (rear), preferably the anode.

Furthermore, the at least one recess preferably has the shape of a

Hole on, wherein the front and the back of the hole are preferably completely covered with sealing material. The shape of the holes can be chosen arbitrarily in principle. It can be, for example, round, oval, angular or star-shaped.

Conveniently, the at least one recess is arranged in the outer region of the polymer electrolyte membrane.

Furthermore, a better tightness can be achieved by providing recesses in the polymer electrolyte membrane at regular intervals, so that the sealing material is sealingly applied to the front and the back of the polymer electrolyte membrane. In this case, a good adhesion of the sealing material to the surface of the polymer electrolyte membrane is not absolutely necessary.

The sealing material should seal the fuel cell during operation of the membrane-electrode assembly so as to best prevent the escape of reaction fluids and / or solvents from the fuel cell. For this purpose, the sealing material on the front and / or the back of the polymer electrolyte membrane, preferably on the front and the back of the polymer

Electrolyte membrane in contact with electroconductive bipolar plates, typically provided with flow field troughs on the sides facing the electrodes, to facilitate the distribution of reactant fluids. The bipolar plates are usually made of graphite or of conductive, heat-resistant plastic.

In combination with the bipolar plates, the sealing material generally seals the gas spaces to the outside. In addition, the sealing material generally also seals the gas spaces between the anode and the cathode. Surprisingly, it was thus found that an improved

Sealing concept can lead to a fuel cell with a prolonged life.

For this reason, the sealing material is preferably designed such that at least one, preferably two, bipolar plates can be sealingly applied to the membrane-electrode unit according to the invention. The sealing effect can be achieved by pressing the composite Bipolarplattθ (n) and inventive membrane-electrode unit can be increased.

To further improve the sealing effect, the contact surface of the sealing material on the front side of the polymer electrolyte membrane with the

Sealing material on the back of the polymer electrolyte membrane, based on the total surface area of the at least one recess as large as possible. It is favorably in the range of 25.0% and 100.0%, preferably in the range of 50.0% and 100.0%, in particular in the range of 75.0% and 100.0%, each based on the total surface area of at least one recess. In this case, the contact surface designates the surface over which the sealing material on the front side of the polymer electrolyte membrane is in contact with the sealing material on the rear side of the polymer electrolyte membrane. The surface of a recess is determined perpendicular to the surface of the polymer electrolyte membrane. Should the surfaces of a recess on the front and on the

Differentiate back side, as the smaller value in the present case is based.

According to another aspect of the present invention, it has proved to be extremely favorable that the contact surface of the sealing material on the front side of the polymer electrolyte membrane and the sealing material on the back of the

Polymer electrolyte membrane has a hole inside. For example, gases can be passed through the membrane-electrode unit through this hole without impairing the functionality of the membrane-electrode unit.

The following figures serve to further illustrate the present

Invention without this being a limitation of the inventive concept.

FIG. 1 is an exploded perspective view of a preferred embodiment. FIG

Embodiment of the Membrane-Electrode Assembly According to the Invention FIG. 2 is a plan view of a preferred embodiment of a membrane-electrode assembly according to the invention

Fig. 3 is a first side view of a preferred embodiment of the membrane electrode assembly according to the invention as. Exploded cross-sectional

Fig. 4 is a second side view of a preferred embodiment of the inventive membrane-electrode assembly in cross-section Fig. 5 is a third side view of a ^"preferred embodiment of the inventive membrane electrode assembly as an exploded cross-section of Fig. 6 is a fourth side view of a preferred embodiment of the membrane according to the invention Electrode unit as a cross section The preferred embodiment of the present invention shown in Fig. 1 comprises two electrochemically active electrodes (1, 3) separated by a polymer electrolyte membrane (5). The surfaces of the polymer electrolyte membrane are in contact with the electrodes (1, 3) in such a way that the first electrode (1) has the front side (visible surface) of the polymer electrolyte membrane (5) and the second electrode (3) each cover the back (not visible) of the polymer electrolyte membrane (5) only partially.

Hereinafter, the area of the front and rear surfaces covered by the electrodes (1, 3) will be referred to as the inner portion of the polymer electrolyte membrane (5) and the portion of the polymer electrolyte membrane (5) not covered by the electrodes designated outer area.

The membrane-electrode unit further comprises sealing material (7, 9) on uncovered surfaces of the front and the back of the polymer

Electrolyte membrane (5), wherein the sealing material (7) the front of the outer region of the polymer electrolyte membrane (5) and the sealing material (9) covers the back of the outer region of the polymer electrolyte membrane (5).

The polymer electrolyte membrane (5) comprises a plurality of recesses (11), which in the present case are in the form of holes and are arranged at uniform intervals in the outer region.

The sealing material (9) on the back of the polymer electrolyte membrane (5) has on its front side, d. H. on the polymer electrolyte membrane (5) facing side of several projecting lugs (13), which also consist of sealing material. The shape, position and arrangement of the projecting lugs (13) on the sealing material (9) is such that the. projecting lugs (13) through the recesses (11) in the polymer electrolyte membrane (5) fit and thus able, the sealing material (9) on the

Rear side of the polymer electrolyte membrane (5) with the sealing material (7) on the front side of the polymer electrolyte membrane (5) through the recesses (11) to connect. The projecting lugs (13) therefore have a plan view. Base area less than or equal to the base of the recesses (11). Furthermore, the height of the projecting lugs (13) is at least equal to the thickness

(Vertical) of the polymer electrolyte membrane (5), so that the projecting lugs can connect the sealing material (7, 9) on both sides of the polymer electrolyte Mambran (5). In addition, the arrangement of the projecting lugs (13) on the front side of the sealing material (9) corresponds to the arrangement of the recesses (11) in the polymer electrolyte membrane (5). Fig. 2 shows the membrane-electrode unit again in plan view. The front side of the polymer electrolyte membrane (5) is covered by the first electrode (1). The second electrode (3, not shown) is symmetrical to the polymer electrolyte membrane (5) on its rear side. Thus, the surface of the polymer electrolyte membrane (5) covered by the first electrode (1) constitutes the inner one

Area of the polymer electrolyte membrane (5) and not through the first electrode

(I) covered surface of the polymer electrolyte membrane (5) is the outer portion of the polymer electrolyte membrane (5).

The recesses (11) in the polymer electrolyte membrane (5), which in the outer

Area disposed annularly around the first electrode (1) and formed in the form of evenly spaced holes are covered by the sealing material (7).

In this case, the sealing material (7) is preferably on the front side of the

Polymer electrolyte membrane (5) applied so that it is in no position in contact with the electrode (1). The gap between the electrode (1) and the sealing material (7) serves to best avoid the build-up of mechanical stresses during heating, which may possibly build up due to possibly different thermal expansion coefficients of the electrode and sealing material.

Although not visible in FIG. 2, for the same reasons, the sealing material (9) is preferably applied to the rear side of the polymer electrolyte membrane (5) such that it is not in contact with the electrode (3) at any point ,

FIG. 3 (exploded view) and FIG. 4 show cross sections through the membrane-electrode assembly, the section being taken perpendicular to the surface of the polymer-electrolyte membrane (5) along a plane A which covers the inner and outer regions of the polymer Electrolyte membrane (5), but no recesses

II 1) in the polymer electrolyte membrane (5) cuts. The course of the plane A is illustrated in FIG. 2.

In Fig. 3, the sealing material (7, 9) above and below the polymer

Electrolyte membrane (5) accordingly in the middle recesses, which can accommodate the electrodes (1, 3). Furthermore, the sealing material (7 ', 9') and the projecting lugs (13 ') can be seen, which are located behind the drawing plane (not hatched elements).

During assembly, the recess in the sealing material (7) on the front side of the polymer electrolyte membrane (5) takes the first electrode (1) and the Recess in the sealing material (9) on the back of the polymer electrolyte membrane (5) the second electrode (3). The elements (7 ', 9 ", 13') located behind the plane of the drawing are largely concealed by the electrodes (1, 3) and the sealing material (7), only in the areas between the first electrode (1) and the sealing material ( 7) and between the second

Electrode (3) and the sealing material (9) can be seen behind the plane of sealing material located (7 ', 9').

FIG. 5 (exploded view) and FIG. 6 show cross-sections through the membrane-electrode assembly, wherein the section perpendicular to the surface of the polymer

Electrolyte membrane (5) along a plane B, which intersects the inner and the outer region of the polymer electrolyte membrane (5) and two recesses (11) in the polymer electrolyte membrane (5), which, along the Plane B, separated by the inner area. The course of the plane B is illustrated in FIG. 2.

In Fig. 5, the sealing material (7, 9) above and below the polymer electrolyte membrane (5) accordingly in the middle recesses, which can accommodate the electrodes (1, 3). In this case, the sealing material (9) projecting lugs (13) and the polymer electrolyte membrane (5) recesses

(11), which can receive projecting lugs (13). Furthermore, the sealing material (7 ', 9') can be seen, which are located behind the drawing plane (not hatched elements).

When assembling the recess in the sealing material (7) takes on the

Front side of the polymer electrolyte membrane (5), the first electrode (1) and the recess in the sealing material (9) on the back of the polymer electrolyte membrane (5) the second electrode (3). Furthermore, the recesses (11) receive the projecting lugs (13), so that the sealing material (7) on the front side of the polymer electrolyte membrane (5) with the sealing material (9) on the back of the polymer electrolyte membrane ( 5) is integrally connected via the projecting lugs (13). The elements (7 ', 9') located behind the plane of the drawing are largely concealed by the electrodes (1, 3). Only in the areas between the first electrode (1) and the sealing material (7) and between the second electrode (3) and the

Sealing material (9) can be seen behind the plane of seal material located (Y ', 9').

The preparation of the membrane-electroderi unit according to the invention will be apparent to those skilled in the art. In general, the various components of the membrane-electrode assembly are superimposed and interconnected by pressure and temperature, usually at a temperature in the Range of 10 to 300 ⁰ C, in particular 2O ⁰ C to 200 ° and at a pressure in the range of 1 to 1000 bar, in particular from 3 to 300 bar, is laminated.

According to a first preferred embodiment of the invention, the preparation of the membrane-electrode assembly comprises the steps of: i) entraining the polymer electrolyte membrane, preferably non-electrode covered areas of the polymer electrolyte membrane, at one or more locations ii) the at least one recess partially or completely filled with sealing material and iii) applies the sealing material on not covered by the electrodes surfaces on the front and the back of the polymer electrolyte membrane, wherein the steps ii) and iii) be carried out such that the sealing material in the at least one recess, the sealing material on the front side of the polymer electrolyte membrane with the sealing material on the back of the

Polymer electrolyte membrane, preferably in one piece, connects.

Step i) can be carried out in a known manner, but in the present context, the cutting and / or punching the at least one recess has proven particularly useful. Furthermore, the

Polymer electrolyte membrane preferably provided with recesses perpendicular to the surface of the polymer electrolyte membrane.

The filling of the at least one recess with sealing material according to step ii) and the application of the sealing material according to step iii) can also be carried out in a manner known per se. if the objective is achieved that the sealing material in the at least one recess connects the sealing material on the front side of the polymer electrolyte membrane with the sealing material, on the back of the polymer electrolyte membrane, preferably in one piece. Therefore, the sealing material is preferably applied to the front and the

Rear side of the polymer electrolyte membrane applied so that it covers the upper and lower end of the recess at least partially, preferably completely. If the polymer electrolyte membrane has a plurality of recesses, then it may possibly be sufficient if the sealing material of the front side and the back side is replaced by only part of the _. Recesses is interconnected.

The application of the sealing material to the polymer electrolyte membrane and the filling of the at least one recess is preferably carried out by thermoplastic processes in the viscoelastic. Condition, which have proven very useful for this purpose injection molding process. In this case, it is expedient to proceed as follows: First, molds are made for the front and the back of the polymer electrolyte membrane, in which one or more recesses, preferably upwardly open channels, are provided for the sealing material. The shape, size and position of the recesses are selected such that a cell sealed to the outside with the desired size of the contact surface of the electrodes and polymer electrolyte membrane is obtained. Conveniently, the layout of the recesses behave on the two forms such as image and mirror image to each other.

In parallel, a membrane-electrode assembly is prepared comprising two electrochemically active electrodes separated by a polymer-electrolyte membrane, the surfaces of the polymer-electrolyte membrane being in contact with the electrodes such that the first Electrode the front of the polymer electrolyte membrane and the second electrode, the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially covered. In this case, the polymer Elektrölyt membrane is further provided with one or more recesses, which connect appropriately not covered by the electrodes surfaces of the front and the back of the polymer electrolyte membrane.

For the production of the membrane-electrode assembly according to the invention: a) the at least one recess provided in the shape of the back filled with sealing material melt, b) the previously described membrane-electrode assembly placed on the mold such that the sealing material melt with the back the polymer electrolyte membrane, preferably with not covered by the electrode surface of the back surface of the polymer electrolyte membrane in contact and the lower end of the at least one recess in the polymer electrolyte membrane is in contact with the sealing material melt, c ) the at least one recess at least partially with

Filled sealing material melt, d) the at least one provided recess in the form of the front filled with sealing material melt, e) the shape of the front placed on the front of the polymer electrolyte membrane such that the sealing material melt in the form of

Front side with the front side of the polymer electrolyte membrane, preferably with not covered by the electrode surface of the front surface of the polymer electrolyte membrane, in contact and the upper end of the at least one recess in the polymer electrolyte membrane with the sealing material melt Shape of the front is in contact, f) the composite of the form of the back, membrane-electrode assembly and the shape of the front side, preferably under pressure, cooled such that the sealing material melt solidifies.

• The finished membrane electrode assembly (MEA) is after cooling and

Removing the molds ready for use and can be used in a fuel cell.

According to a second preferred embodiment of the present invention for producing the membrane electrode assembly according to the invention, the

Applying the sealing material to the polymer electrolyte membrane by extrusion. Here again, a membrane-electrode assembly is prepared, which comprises two electrochemically active electrodes which are separated by a polymer electrolyte membrane, wherein the surfaces of the polymer electrolyte membrane are in contact with the electrodes such that the first

Electrode the front of the polymer electrolyte membrane and the second electrode, the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially covered. The polymer electrolyte membrane is further provided with one or more recesses, which are usefully not covered by the electrode surfaces of the front and the back of the

Connect polymer electrolyte membrane together.

For applying the sealing material, this is preferably extruded and applied to the front and the back of the polymer electrolyte membrane such that the sealing material at least partially covers at least one recess from both sides. The composite of sealing material and membrane-electrode assembly is then compressed such that the sealing material on the front side of the polymer electrolyte membrane is in contact with the sealing material on the back side of the polymer electrolyte membrane.

According to a third preferred embodiment of the present invention, the production of the membrane-electrode assembly according to the invention comprises the steps that one ^prepares' a membrane electrode assembly comprising two electrochemically active electrodes separated by a polymer electrolyte membrane, wherein the surfaces of the polymer electrolyte membrane are in contact with the electrodes in such a way that the first electrode, the front side of the polymer electrolyte membrane and the second electrode, the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially, covered.

Next, the sealant is applied to the front and rear sides of the polymer electrolyte membrane and the composite is provided Sealing material and membrane-electrode assembly with at least one recess, preferably with at least one hole passing through the sealing material on the front and the back of the polymer electrolyte membrane and through the polymer electrolyte membrane. The at least one recess is at least partially filled with sealing material and in this way connects the sealing material on the front side of the polymer electrolyte membrane with the sealing material on the back side of the polymer electrolyte membrane. Conveniently, the application of the coating material is carried out simultaneously with the generation of the at least one recess, by piercing the at least one recess by means of an inner hollow shape and the

Removing the mold at least partially directly fills the resulting at least one recess with sealing material by passing sealing material into the recess through the interior of the mold.

According to a fourth preferred embodiment of the present invention, the preparation of the membrane-electrode assembly comprises the steps of preparing a membrane-electrode assembly comprising two electrochemically active electrodes separated by a polymer electrolyte membrane, wherein the Surfaces of the polymer electrolyte membrane are in contact with the electrodes in such a way that the first electrode, the front of the polymer electrolyte

Membrane and the second electrode, the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially covered.

Next, the polymer electrolyte membrane is placed in a suitable shape, provided with at least one recess, preferably at least one

Hole, and then applies sealing material, preferably by injection molding, on the front and the back of the polymer electrolyte membrane. Conveniently, the application of the sealing material takes place simultaneously with the production of the at least one recess by puncturing the at least one recess by means of an internally hollow shape and at least partially fills the resulting at least one recess with sealing material when removing the mold by passing through the interior of Form the sealing material into the recess.

According to a fifth preferred embodiment of the present invention, the preparation of the membrane-electrode assembly comprises the steps of preparing a membrane-electrode assembly comprising two electrochemically-active electrodes separated by a polymer-electrolyte membrane, wherein the Surfaces of the polymer electrolyte membrane are in contact with the electrodes in such a way that the first electrode, the front of the polymer electrolyte

Membrane and the second electrode, the back of the polymer electrolyte membrane in each case partially or completely, preferably only partially covered. Next, one provides the polymer electrolyte membrane with at least one recess, preferably with at least one hole, and then applies preformed sealing material to the front and the back of the polymer electrolyte membrane. This has the applied on the back

Seal material on its side facing the polymer electrolyte membrane on one or more projecting lugs, which also consist of sealing material. The shape, position and arrangement of the projecting lugs on the sealing material is such that the projecting lugs fit through the recesses in the polymer electrolyte membrane and thus are capable of sealing material on the backside of the polymer electrolyte membrane connect with the sealing material on the front of the polymer electrolyte membrane through the recesses. Conveniently, the projecting lugs of the sealing material on the rear side of the polymer electrolyte membrane are then in a further step with the sealing material on the front of the

Polymer electrolyte membrane, preferably by plastic welding, connected.

In the context of this embodiment, it has proved to be particularly particularly according to the invention that the sealing material on the front side of the polymer electrolyte membrane has one or more recesses, preferably at least one hole, which surrounds the protruding projections of the sealing material on the rear side of the polymer electrolyte. Can accommodate membrane. The assembly of the membrane-electrode assembly is then preferably such that the protruding lugs of the sealing material through the polymer electrolyte membrane and the recesses in the sealing material on the front of the

Polymer electrolyte membrane is inserted and connects the sealing material on the front of the polymer electrolyte membrane with the projecting lugs of the sealing material on the back of the polymer electrolyte membrane, preferably welded.

It has been found, particularly surprisingly, that membrane electrode units according to the invention can be stored or shipped without problems due to their dimensional stability under fluctuating ambient temperatures and air humidity. Even after prolonged storage or after shipment to places with significantly different climatic conditions, the dimensions of the

Membrane electrode units without any problems for installation in fuel cell stacks. The membrane-electrode assembly then no longer needs to be conditioned on-site for external installation, which simplifies fuel cell fabrication and saves time and cost.

An advantage of preferred membrane electrode assemblies is that they allow the operation of the fuel cell at temperatures above 120 ⁰ C. This applies to gaseous and liquid fuels, such as hydrogen-containing gases, which are prepared for example in an upstream reforming step of hydrocarbons. For example, oxygen or air can be used as the oxidant.

Another advantage of preferred membrane-electrode assemblies is that they have a high tolerance to carbon monoxide in operation above 120 ⁰ C even with pure platinum catalysts, ie without a further alloying ingredient. At temperatures of 160 ⁰ C, for example, more than 1% CO may be contained in the fuel gas, without this leading to a significant reduction in the performance of

Fuel cell leads.

Preferred membrane-electrode assemblies can be operated in fuel cells without the need to humidify the fuel gases and oxidants despite the possible high operating temperatures. The fuel cell is still stable and the membrane does not lose its conductivity. This simplifies the entire fuel cell system and brings additional cost savings, since the management of the water cycle is simplified. Furthermore, this also improves the behavior at temperatures below 0 ^° C. of the fuel cell system.

Surprisingly, preferred membrane-electrode assemblies allow the fuel cell to be cooled down to room temperature and below, and then put back into service without sacrificing performance. On the other hand, conventional phosphoric acid-based fuel cells sometimes have to switch off when the fuel cell system is switched off

Temperature above 80 ⁰ C to avoid irreversible damage.

Furthermore, the preferred membrane-electrode assemblies of the present invention exhibit very high long-term stability. It has been found that a fuel cell according to the invention can be operated continuously for long times, for example more than 5000 hours, at temperatures of more than 120 ^° C. with dry reaction gases, without noticeable performance degradation being detectable. The achievable power densities are very high even after such a long time.

In this case, the fuel cells according to the invention, even after a long time, for example, more than 5000 hours, a high rest voltage, which is preferably at least 2000 mV after this time. To measure the quiescent voltage, a fuel cell with a hydrogen flow on the anode and an air

Flow operated on the cathode without power. The measurement is made by the fuel cell from a current of 0.2 A / cm ² to the de-energized state is switched and then there 52 minutes the rest voltage is recorded. The value after 5 minutes is the corresponding resting potential. The measured values of open circuit voltage apply for a temperature of 160 ⁰ C. Moreover, the fuel cell according to this time is preferably a small gas passage (gas cross-over). To measure the cross-overs, the anode side of the

Fuel cell operated with hydrogen (5 L / h), the cathode with nitrogen (5L / h). The anode serves as a reference and counter electrode. The cathode as a working electrode. The cathode is set to a potential of 0.5 V and oxidized through the membrane diffusing hydrogen at the cathode mass transport-limited. The resulting current is a measure of the hydrogen permeation rate.

The current is <3 mA / cm ² , preferably <2 mA / cm ² , more preferably <1 mA / cm ² in a 50 cm ² cell. The measured values of the H ₂ cross-over open-circuit voltage apply to a temperature of 16O ° C.

In addition, the membrane-electrode assemblies according to the invention can be produced inexpensively and easily.

For more information about membrane-electrode assemblies, reference is made to the literature, and more particularly to US-A-4,191,618, US-A-4,212,714 and US-A-4,333,805. The references cited in the abovementioned references [US Pat.

4,191,618, US-A-4,212,714 and US-A-4,333,805] with regard to the construction and manufacture of membrane-electrode assemblies, as well as the electrodes to be selected, gas diffusion layers and catalysts is also part of the description.

Claims

claims:

1. Membrane electrode assembly comprising a) two electrochemically active electrodes (1, 3) which are separated by a polymer electrolyte membrane (5), wherein the surfaces of the polymer

Electrolyte membrane (5) with the electrodes (1, 3) are in contact, that the first electrode (1) the front of the polymer electrolyte membrane (5) and the second electrode (3) the back of the polymer electrolyte - Membrane (5) each partially or completely covered, b) sealing material (7, 9) on the front and the back of the polymer

Electrolyte membrane (5), characterized in that the polymer electrolyte membrane (5) has one or more recesses (11) and the sealing material (7) on the front side of the polymer electrolyte membrane (5) with the sealing material ( 9) on the back of the ^■

Polymer electrolyte membrane (5) is in contact.

2. membrane electrode assembly according to claim 1, characterized in that the at least one recess (11) in the form of a hole through the polymer electrolyte membrane (5) is formed.

3. Membrane _: Electrode unit according to claim 1 or 2, characterized in that the polymer electrolyte membrane (5) comprises an inner and an outer region, wherein only the front and the back of the inner region of the polymer electrolyte Membrane (5) with the electrodes (1, 3) are in contact.

4. membrane electrode assembly according to claim 3, characterized in that the at least one recess (1 1) in the outer region of the polymer electrolyte membrane (5) is arranged.

5. membrane-electrolyte-unit according to one or more of the preceding claims, characterized in that the sealing material (7, 9) is a thermoplastically yerarbeitbares material.

6. membrane electrode assembly according to one or more of the preceding claims, characterized in that the sealing material (7, 9) is a fluoropolymer.

7. membrane electrode assembly according to one or more of the preceding

Claims, characterized in that the polymer electrolyte membrane (5) 'comprises polyazoles.

8. membrane electrode assembly according to one or more of the preceding claims, characterized in that the polymer electrolyte membrane (5) is doped with an acid.

9. membrane electrode assembly according to claim 8, characterized in that the polymer electrolyte membrane (5) is doped with phosphoric acid.

10. membrane electrode assembly according to claim 9, characterized in that the concentration of phosphoric acid is at least 50% wt .-%.

Membrane electrode assembly according to one or more of the preceding claims, characterized in that the polymer electrolyte membrane (5) is obtainable by a process comprising the steps A) mixing of one or more aromatic tetra-amino compounds with one or more aromatic carboxylic acids or their esters containing at least two acid groups per carboxylic acid monomer, or mixing one or more aromatic and / or heteroaromatic diaminocarboxylic acids in polyphosphoric acid to form a solution and / or dispersion,

B) applying a layer using the mixture according to step A) on a carrier or on an electrode,

C) heating the sheet / layer obtainable according to step B) under inert gas to temperatures of up to 350 ⁰ C, preferably up to 28O ⁰ C, to form the polyazole polymer,

D) treatment of the membrane formed in step C) until it is self-supporting.

12. membrane electrode assembly according to claim 9, 10 or 11, characterized in that the doping degree is between 3 and 50.

13. Membrane electrode unit according to one or more of the preceding claims, characterized in that the polymer electrolyte membrane (5) comprises polymers obtainable by polymerization of monomers comprising phosphonic acid groups and / or monomers comprising sulfonic acid groups.

14. membrane electrode assembly according to one or more of the preceding claims, characterized in that at least one of the electrodes (1, 3) is made of a compressible material.

15. A process for producing a membrane-electrode assembly according to one or more of the preceding claims, wherein the components a) and b) the membrane electrode assembly in the desired order, characterized in that i) the polymer electrolyte membrane (5) at one or more locations with at least one recess (11) provides, ii) the at least one recess (11) partially or completely with

Dichtungsmateriai fills and iii) the sealing material (7, 9) not covered by the electrodes

Surfaces on the front and back of the polymer electrolyte membrane

(5), wherein the steps ii) and iii) are such that the sealing material in the at least one recess (11) the sealing material (7) on the front side of the polymer electrolyte membrane (5) with the sealing material (9) on the back of the polymer electrolyte membrane (5) connects.

16. The method according to claim 15, characterized in that the filling of the at least one recess (11) with sealing material and the application of the sealing material (J, 9) to the polymer electrolyte membrane (5) by thermoplastic processing takes place in the viscoelastic state.

17. The method according to claim 16, characterized in that the

Gasket material by injection molding on the polymer electrolyte membrane (5) applies.

18. Fuel cell comprising at least one membrane-electrode unit according to one or more of claims 1 to 14.