Membrane electrode assembly for a fuel cell, method for preparing the membrane electrode assembly, fuel cell system and vehicle

Patent metadata

Field	Value
Publication number	US-10593979-B2
Application number	US-201514950204-A
Country	US
Kind code	B2
Filing date	Nov 24, 2015
Priority date	Nov 28, 2014
Publication date	Mar 17, 2020
Grant date	Mar 17, 2020

Abstract

A membrane electrode assembly for a fuel cell, with a membrane, a catalyst layer ( 16 ) and a gas diffusion layer. The catalyst layer ( 16 ) has a first side facing the membrane and a second side facing the gas diffusion layer. In the catalyst layer ( 16 ) an ionomer content increases towards the membrane. The catalyst layer ( 16 ) has a first sublayer ( 22 ) in which catalyst particles ( 26 ) are coated with a first ionomer ( 28 ). The catalyst layer ( 16 ) further has a second sublayer ( 24 ) with a second ionomer ( 32 ) which is closer to the membrane than the first sublayer ( 22 ). Pores ( 30 ) are present at least between the coated catalyst particles ( 26 ). Further, a method for preparing such a membrane electrode assembly, a fuel cell system and a vehicle with a fuel cell system.

First claim

The invention claimed is:

1. A membrane electrode assembly for a fuel cell, comprising
a membrane ( 12 ),
a catalyst layer ( 16 ) and
a gas diffusion layer ( 14 ),
wherein the catalyst layer ( 16 ) has a first side ( 18 ) facing the membrane ( 12 ) and a second side ( 20 ) facing the gas diffusion layer ( 14 ),
wherein in the catalyst layer ( 16 ) an ionomer content increases towards the membrane,
wherein the catalyst layer ( 16 ) comprises
a first sublayer ( 22 ) in which supported catalyst particles ( 26 ) are coated with a first ionomer ( 28 ), and
a second sublayer ( 24 ) comprising particles of a second ionomer ( 32 ) free of catalyst, the second sublayer ( 24 ) being closer to the membrane ( 12 ) than the first sublayer ( 22 ), the first sublayer ( 22 ) being closer to the gas diffusion layer ( 12 ) than the second sublayer ( 24 ),

wherein pores ( 30 ) are present at least between the coated catalyst particles ( 26 ) and also between the particles of the second ionomer ( 32 ),
wherein a porosity of the catalyst layer ( 16 ) increases from the first side ( 18 ) towards the second side ( 20 ) of the catalyst layer ( 16 ), and
wherein the first and/or the second ionomer is/are a mixture of an ionomer and one or more polymers.

2. The membrane electrode assembly according to claim 1 , wherein within the first sublayer ( 22 ) an average thickness of the coating is inferior to an average diameter of the catalyst particles ( 26 ).

3. The membrane electrode assembly according to claim 1 , wherein within the catalyst layer ( 16 ) the coating of the coated catalyst particles ( 26 ) avoids a contact between the second ionomer ( 32 ) and the catalyst particles ( 26 ).

4. The membrane electrode assembly according to claim 1 , wherein the acidity and/or the molecular mass per sulfonic acid group and/or a composition of the first ionomer ( 28 ) differs from that of the second ionomer ( 32 ).

5. The membrane electrode assembly according to claim 1 , wherein the mixture of an ionomer and one or more polymers contains a polymer selected from the list comprising fluoropolymers, perfluorinated elastomers, perfluoropolyethers, polyaromatic polymers, as well as mixtures or combinations thereof.

6. The membrane electrode assembly according to claim 1 , wherein the first sublayer ( 22 ) is obtained by mixing a powder containing the catalyst particles ( 26 ) with the first ionomer ( 28 ), wherein the catalyst layer ( 16 ) is obtained by application of an ink containing the second ionomer ( 32 ) onto the at least partially consolidated first sublayer ( 22 ).

7. The membrane electrode assembly according to claim 1 , wherein the membrane electrode assembly ( 10 ) is prepared by a method comprising:
in a first step of the preparation of the catalyst layer ( 16 ) mixing a powder containing the catalyst particles ( 26 ) with the first ionomer ( 28 ) to obtain the first sublayer ( 22 ), and
in a second step, applying an ink containing the second ionomer ( 32 ) onto the at least partially consolidated first sublayer ( 22 ) to obtain the second sublayer ( 24 ).

8. A fuel cell system, with a fuel cell stack ( 78 ) comprising a plurality of fuel cells, wherein each fuel cell comprises a membrane electrode assembly ( 10 ) according to claim 1 , and wherein each membrane electrode assembly ( 10 ) is arranged between a first separator plate ( 92 ) and a second separator plate ( 94 ).

9. A vehicle with a fuel cell system ( 76 ) according to claim 8 .

10. The membrane electrode assembly according to claim 1 , wherein a porosity of the cathode catalyst layer ( 16 ) increases from the first side ( 18 ) towards the second side ( 20 ) of the catalyst layer ( 16 ).

11. The membrane electrode assembly according to claim 5 , wherein the fluoropolymer is selected from polyvinylidene difluoride, polytetrafluoroethylene and Teflon® AF, wherein the perfluorinated elastomer is selected from copolymers of hexafluoropropylene and vinylidene fluoride, and wherein the polyaromatic polymer is selected from polyethersulfones, siloxanic polymers, and polybenzimidazole.

Assignees

• Daimler Ag
• Ford Motor Co

Inventors

• Chuy Carmen
• Mcdermid Scott
• Bai Kyoung
• Ngo Tran

Classifications

• H01M4/8636

  with a gradient in another property than porosity (H01M4/861 takes precedence) · CPC title

• H01M8/1004 Primary

  characterised by membrane-electrode assemblies [MEA] (H01M8/12 takes precedence) · CPC title

• H01M4/8663

  Selection of inactive substances as ingredients for catalytic active masses, e.g. binders, fillers · CPC title

• H01M4/861

  with a gradient in the porosity · CPC title

• H01M4/8828

  Coating with slurry or ink · CPC title