Fuel cell electrode with gradient catalyst structure
US-9761899-B2 · Sep 12, 2017 · US
US8993472B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-8993472-B2 |
| Application number | US-99858609-A |
| Country | US |
| Kind code | B2 |
| Filing date | Nov 6, 2009 |
| Priority date | Nov 7, 2008 |
| Publication date | Mar 31, 2015 |
| Grant date | Mar 31, 2015 |
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Layered catalyst structures for fuel cells, particularly for a Proton Exchange Membrane Fuel Cell (PEMFC), are produced by a reactive spray deposition technology process. The catalyst layers so produced contain particles sized between 1 and 15 nm and clusters of such particles of a catalyst selected from the group consisting of platinum, platinum alloys with transition metals, mixtures thereof and non-noble metals. The catalyst layers without an electrically conducting supporting medium exhibit dendritic microstructure, providing high electrochemically active surface area and electron conductivity at ultra-low catalyst loading. The catalyst layers deposited on an electrically conducting medium, such as carbon, exhibit three-dimensional functional grading, which provides efficient utilization as a catalyst, high PEMFC performance at the low catalyst loading, and minimized limitations caused by reactant diffusion and activation. The catalytic layers may be produced by a single-run deposition method.
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The invention claimed is: 1. A catalyst layer structure for a fuel cell electrode, the structure comprising a catalyst layer comprising catalyst particles 1-15 nm in size, the layer having a catalyst loading not more than 0.1 mg/cm 2 and rendering PEM fuel cell performance of at least 0.6 W/cm 2 , the catalyst layer further comprising a proton conducting ionomer, and the structure having a catalyst concentration gradient in at least the z direction, the concentration increasing to…
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