Fuel cells and electrolyzer electrodes containing non-ionomeric binders

Patent metadata

Field	Value
Publication number	US-2025385272-A1
Application number	US-202418740847-A
Country	US
Kind code	A1
Filing date	Jun 12, 2024
Priority date	Jun 12, 2024
Publication date	Dec 18, 2025
Grant date	—

Abstract

An electrode of an electrochemical device includes a carbon-based support structure, an ionically conductive material dispersed on and within the support structure, a catalyst dispersed on and within the support structure, and a non-ionomeric hydrocarbon-based binder dispersed on the support structure. The ionically conductive material enables the transport of protons across the electrode, the catalyst promotes a chemical reaction of a fuel received at the electrode, and the binder retains the electrode. The electrode may be included in an electrochemical device, such as a fuel cell.

First claim

What is claimed is:

1 . An electrode of an electrochemical device, the electrode comprising:
a carbon-based support structure; an ionically conductive material dispersed on and within the support structure, the ionically conductive material enabling the transport of protons across the electrode; a catalyst dispersed on and within the support structure, the catalyst promoting a chemical reaction of a fuel received at the electrode; and a non-ionomeric hydrocarbon-based binder dispersed on the support structure, the binder retaining the electrode.

2 . The electrode of claim 1 , wherein the ionically conductive material comprises a sulfate.

3 . The electrode of claim 1 , wherein the catalyst comprises at least one from the group consisting of (i) platinum, and (ii) platinum alloy.

4 . The electrode of claim 3 , wherein a ratio of platinum to a mass of carbon in the support structure is less than or equal to 0.6.

5 . The electrode of claim 1 , wherein the binder comprises at least one of the group consisting of (i) carboxymethyl cellulose, (ii) polyninylidene fluoride, and (iii) styrene butadiene rubber.

6 . The electrode of claim 5 , wherein a ratio of carboxymethyl cellulose in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

7 . The electrode of claim 5 , wherein a ratio of polyvinylidene fluoride in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

8 . The electrode of claim 1 , wherein the catalyst and the binder, combined with a solvent, are dispersed on the support structure as a catalyst dispersion ink.

9 . The electrode of claim 8 , wherein the solvent is devoid of alcohol.

10 . The electrode of claim 1 , wherein a thickness of catalyst dispersed on the support structure is less than or equal to 20 microns.

11 . An electrochemical device comprising:
an electrode comprising:
a carbon-based support structure;
an ionically conductive material comprising sulfate and dispersed on and within the support structure, the ionically conductive material enabling the transport of protons across the electrode;
a catalyst comprising platinum and dispersed on and within the support structure, the catalyst promoting a chemical reaction of a fuel received at the electrode, and the catalyst including a ratio of platinum to a mass of carbon in the support structure that is less than or equal to 0.6; and
a non-ionomeric hydrocarbon-based binder dispersed on the support structure, the binder retaining the electrode, and the binder comprising at least one of the group consisting of (i) carboxymethyl cellulose, (ii) polyninylidene fluoride, and (iii) styrene butadiene rubber.

12 . The electrochemical device of claim 11 , wherein a ratio of carboxymethyl cellulose in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

13 . The electrochemical device of claim 11 , wherein a ratio of polyvinylidene fluoride in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

14 . The electrochemical device of claim 11 , wherein the catalyst and the binder, combined with a solvent, are dispersed on the support structure as a catalyst dispersion ink.

15 . The electrochemical device of claim 14 , wherein the solvent is devoid of alcohol.

16 . The electrochemical device of claim 11 , wherein a thickness of catalyst dispersed on the support structure is less than or equal to 20 microns.

17 . A vehicle comprising:
a fuel cell comprising:
an electrode comprising:
a carbon-based support structure;
an ionically conductive material comprising sulfate and dispersed on and within the support structure, the ionically conductive material enabling the transport of protons across the electrode;
a catalyst comprising platinum and dispersed on and within the support structure, the catalyst promoting a chemical reaction of a fuel received at the electrode, and the catalyst including a ratio of platinum to a mass of carbon in the support structure that is less than or equal to 0.6; and
a non-ionomeric hydrocarbon-based binder dispersed on the support structure, the binder retaining the electrode, and the binder comprising at least one of the group consisting of (i) carboxymethyl cellulose, (ii) polyninylidene fluoride, and (iii) styrene butadiene rubber.

18 . The vehicle of claim 17 , wherein a ratio of carboxymethyl cellulose in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

19 . The vehicle of claim 17 , wherein a ratio of polyninylidene fluoride in the binder to the mass of carbon in the support structure is less than or equal to 0.2.

20 . The vehicle of claim 17 , wherein the catalyst and the binder, combined with a solvent, are dispersed on a substrate as a catalyst dispersion ink with a thickness of catalyst dispersed on the substrate being less than or equal to 20 microns.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Ramaswamy Nagappan
• Yarlagadda Venkata Raviteja
• Koestner Roland J
• Kumaraguru Swaminatha P

Classifications

• B60L50/72

  Constructional details of fuel cells specially adapted for electric vehicles · CPC title

• H01M4/926

  on carbon or graphite · CPC title

• H01M2250/20

  Fuel cells in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M4/8668 Primary

  Binders · CPC title

• Y02E60/50

  Fuel cells · CPC title