Electrodes comprising liquid/gas diffusion layers and systems and methods for making and using the same

Patent metadata

Field	Value
Publication number	US-2025023059-A1
Application number	US-202218684264-A
Country	US
Kind code	A1
Filing date	Aug 16, 2022
Priority date	Aug 16, 2021
Publication date	Jan 16, 2025
Grant date	—

Abstract

The presently disclosed subject matter relates to devices, systems, and methods for fabricating a solid polymer electrolyte electrode assembly are provided. One or more electrode for a solid polymer electrolyte electrode assembly includes a porous substrate configured as a liquid/gas diffusion layer and an ionomer-free catalyst coated on the substrate.

First claim

1 . An electrode for a solid or liquid electrolyte electrode assembly, the electrode comprising:
a substrate comprising one or more porous material layer; and an ionomer-free catalyst coated on the substrate, wherein the ionomer-free catalyst comprises an electroplated iridium nanosheet that is coated on the substrate.

2 . The electrode of claim 1 , wherein the substrate further comprises one or more nonporous material layer.

3 . The electrode of claim 1 , wherein the one or more porous material layer comprises one or more liquid/gas diffusion layer having a thickness in a range of about 25 μm to about 500 μm.

4 . The electrode of claim 3 , wherein the one or more liquid/gas diffusion layer comprises a titanium liquid/gas diffusion layer having a thickness in a range of about 25 μm to about 200 μm.

5 . The electrode of claim 3 , wherein the one or more liquid/gas diffusion layer comprises a plurality of pores each having a hydraulic diameter in a range of about 25 μm to about 400 μm and a porosity of about 20% to about 70%.

6 . The electrode of claim 1 , wherein the one or more porous material layer comprises one or more metal-based or carbon-based or composite liquid/gas diffusion layer selected from the group consisting of a patterned porous sheet, a felt, a cloth, a powder, a mesh, a foam, a paper, and combinations thereof.

7 . The electrode of claim 1 , wherein the one or more porous material layer comprises a surface coating selected from the group consisting of a nitride, a metal, a carbide, a composite, and combinations thereof.

8 .- 15 . (canceled)

16 . A solid polymer electrolyte electrode assembly comprising:
a solid polymer electrolyte membrane; a liquid/gas diffusion layer arranged on one side of the solid polymer electrolyte membrane; and an ionomer-free catalyst coated on the liquid/gas diffusion layer, wherein the ionomer-free catalyst comprises an electroplated iridium nanosheet.

17 . A method for fabricating a solid polymer electrolyte electrode assembly, the method comprising:
providing a substrate comprising one or more porous material layer; coating an ionomer-free catalyst on the substrate, wherein the ionomer-free catalyst comprises an electroplated iridium nanosheet that is coated on the substrate; and coupling the substrate to a solid polymer electrolyte membrane.

18 . The method of claim 17 , wherein providing the substrate comprises modifying a surface of the porous substrate to reduce electrical resistance of the substrate, to improve catalyst activity, and combinations thereof.

19 . The method of claim 18 , wherein modifying the surface of the substrate comprises forming a surface coating on the substrate, the surface coating being selected from the group consisting of a nitride, a metal, a carbide, a composite, and combinations thereof that reduce an interfacial contact resistance, improve catalyst activity, and combinations thereof.

20 . The method of claim 18 , wherein modifying the surface of the substrate comprises treating the substrate with hydrochloric acid to form pillar-like surface structures that reduce an interfacial contact resistance and increase a surface area of the substrate.

21 . The method of claim 18 , wherein modifying the surface of the substrate comprises treating the substrate with oxalic acid to form smooth surface structures that reduce an interfacial contact resistance of the substrate.

22 .- 23 . (canceled)

24 . The method of claim 17 , wherein coating a catalyst on the substrate comprises selectively electroplating an iridium nanosheet on the substrate at a temperature in a range of about 80° C. to about 90° C. and ambient pressure.

25 .- 28 . (canceled)

29 . The method of claim 17 , wherein the substrate further comprises one or more nonporous material layer.

30 . A dual electrode assembly for a solid polymer electrolyte device comprising:
a solid polymer electrolyte membrane; a first substrate arranged on a first side of the solid polymer electrolyte membrane; a second substrate arranged on a second side of the solid polymer electrolyte membrane substantially opposing the first side; an ionomer-free anode catalyst coated on the first substrate, wherein the ionomer-free anode catalyst comprises an iridium nanosheet catalyst layer that is electroplated on the first substrate; and an ionomer-free cathode catalyst coated on the second substrate.

31 . The dual electrode assembly of claim 30 , wherein one or both of the first substrate or the second substrate comprises one or more liquid/gas diffusion layer having a thickness in a range of about 25 μm to about 500 μm.

32 . The dual electrode assembly of claim 30 , wherein one or both of the first substrate or the second substrate comprises one or more metal-based or carbon-based or composite liquid/gas diffusion layer selected from the group consisting of a patterned porous sheet, a felt, a cloth, a powder, a mesh, a foam, a paper, and combinations thereof.

33 . The dual electrode assembly of claim 30 , wherein one or both of the first substrate or the second substrate comprises a surface coating selected from the group consisting of a nitride, a metal, a carbide, a composite, and combinations thereof.

34 .- 38 . (canceled)

39 . The dual electrode assembly of claim 30 , wherein the ionomer-free cathode catalyst comprises a platinum nanosheet grown or electroplated on the second substrate.

40 . The dual electrode assembly of claim 30 , wherein the ionomer-free cathode catalyst comprises a MoS 2 nanosheet grown on the second substrate.

Assignees

• Univ Tennessee Res Found

Inventors

• Zhang feng yuan
• Ding Lei
• Li Kui
• Xie Zhiqiang
• Wang Weitian
• Yu Shule

Classifications

• H01M4/8657

  layered · CPC title

• C25B11/032

  Gas diffusion electrodes · CPC title

• H01M8/1004

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

• H01M2008/1095

  Fuel cells with polymeric electrolytes · CPC title

• H01M4/8817

  Treatment of supports before application of the catalytic active composition (coated porous composites H01M8/0245) · CPC title