Conductive polymer layers to limit transfer of fuel reactants to catalysts of fuel cells to reduce reactant crossover

Patent metadata

Field	Value
Publication number	US-9515340-B1
Application number	US-201113081381-A
Country	US
Kind code	B1
Filing date	Apr 6, 2011
Priority date	Apr 6, 2011
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

An apparatus of an aspect includes a fuel cell catalyst layer. The fuel cell catalyst layer is operable to catalyze a reaction involving a fuel reactant. A fuel cell gas diffusion layer is coupled with the fuel cell catalyst layer. The fuel cell gas diffusion layer includes a porous electrically conductive material. The porous electrically conductive material is operable to allow the fuel reactant to transfer through the fuel cell gas diffusion layer to reach the fuel cell catalyst layer. The porous electrically conductive material is also operable to conduct electrons associated with the reaction through the fuel cell gas diffusion layer. An electrically conductive polymer material is coupled with the fuel cell gas diffusion layer. The electrically conductive polymer material is operable to limit transfer of the fuel reactant to the fuel cell catalyst layer.

First claim

What is claimed is:

1. An apparatus consisting essentially of comprising: an anode catalyst layer, the anode catalyst layer operable to catalyze a reaction involving a fuel reactant; an anode electrode comprising an anode input to receive one or more reactants; an anode gas diffusion layer coupled to and disposed between the anode catalyst layer and the anode electrode, the anode gas diffusion layer including a porous electrically conductive material, the porous electrically conductive material operable to allow the fuel reactant to transfer through the anode gas diffusion layer to reach the anode catalyst layer and operable to conduct electrons associated with the reaction through the anode gas diffusion layer; and an electrically conductive polymer material disposed between the anode catalyst layer and the anode electrode, the electrically conductive polymer material operable to limit transfer of the fuel reactant to the anode catalyst layer;
wherein the electrically conductive polymer material comprises at least one electrical conductivity enhancing additive selected from carbon nanotubes, fullerenes, graphenes, carbon particles, carbon nanoparticles, carbon nanomaterials, metal particles, metal nanoparticles, metal nanomaterials, conductive particles, conductive nanoparticles, and combinations thereof.

2. The apparatus of claim 1 , wherein the electrically conductive polymer material comprises a substantially non-porous layer coupled adjacent to the anode gas diffusion layer.

3. The apparatus of claim 1 , wherein the electrically conductive polymer material comprises a layer coupled between the anode gas diffusion layer and the anode catalyst layer.

4. The apparatus of claim 1 , wherein the electrically conductive polymer material is disposed between and coupled to the anode gas diffusion layer and the anode catalyst layer.

5. The apparatus of claim 1 , wherein the electrically conductive polymer material is disposed between and coupled to the anode gas diffusion layer and the anode electrode.

6. The apparatus of claim 1 , wherein the electrically conductive polymer material is included within the anode gas diffusion layer.

7. The apparatus of claim 1 , wherein the electrically conductive polymer material comprises at least one electrically conductive polymer selected from a group consisting of thiophene polymers, polythiophenes, 3-alkyl thiophene polymers, 3,4-ethyl enedioxythiophene polymers, poly(3,4-ethylenedioxythiophenes) (PEDOTs), benzothiazole polymers, benzothiadiazole polymers, phenylene sulfide polymers, poly(p-phenylene sulfides), pyrole polymers, polypyrroles, carbazole polymers, polycarbazoles, indole polymers, polyindoles, azepine polymers, polyazepines, analine polymers, polyanilines, acetylene polymers, polyacetylenes, fluorene polymers, polyfluorenes, phenylene polymers, polyphenylenes, pyrene polymers, polypyrenes, azuelene polymers, polyazulenes, naphthalene polymers, polynaphthalenes, phenylene vinylene polymers, poly(p-phenylene vinylenes), derivatives thereof, and combinations thereof.

8. The apparatus of claim 1 , wherein the electrically conductive polymer material comprises an electrically conductive organic polymer having one of acidic functional groups and basic functional groups.

9. The apparatus of claim 1 , wherein the electrically conductive polymer material comprises at least one electrical conductivity enhancing additive that is a dopant operable to increase the conductivity of the electrically conductive polymer material.

10. The apparatus of claim 1 , wherein the electrically conductive polymer material is operable to limit the transfer of the fuel reactant to the anode catalyst layer to a rate that is at least five times less than a rate that the fuel reactant is able to transfer across the anode gas diffusion layer.

11. The apparatus of claim 1 , wherein the electrically conductive polymer material is operable to limit the transfer of the fuel reactant into the anode catalyst layer to not more than 30% greater than the consumption rate of the fuel reactant.

12. The apparatus of claim 1 , wherein the fuel reactant comprises one of an alkanol having from one to ten carbons and an alkane having from one to ten carbons.

13. The apparatus of claim 1 , wherein the porous electrically conductive material of the anode gas diffusion layer comprises at least one of a porous electrically conductive carbon material, a carbon cloth, a carbon paper, a carbon foam, a porous electrically conductive graphite material, a graphite cloth, a graphite paper, and a graphite foam.

14. An apparatus consisting essentially of an anode comprising: an input to receive a fuel reactant; a gas diffusion layer coupled with the input; an anode catalyst coupled with the gas diffusion layer, the an anode catalyst operable to catalyze a reaction involving the fuel reactant; and an electrically conductive polymer layer disposed between the input and the an anode catalyst, the electrically conductive polymer layer operable to limit transfer of the fuel reactant into the an anode catalyst; a cathode; and a polymer electrolyte membrane coupled between the anode and the cathode;
wherein the electrically conductive polymer layer comprises at least one electrical conductivity enhancing additive selected from carbon nanotubes, fullerenes, graphenes, carbon particles, carbon nanoparticles, carbon nanomaterials, metal particles, metal nanoparticles, metal nanomaterials, conductive particles, conductive nanoparticles, and combinations thereof.

15. The apparatus of claim 14 , wherein the electrically conductive polymer layer comprises a substantially non-porous electrically conductive polymer layer coupled adjacent to the gas diffusion layer.

16. The apparatus of claim 14 , wherein the electrically conductive polymer layer is coupled between the gas diffusion layer and the catalyst, and further comprising a second electrically conductive polymer layer coupled between the input and the gas diffusion layer.

17. The apparatus of claim 14 , wherein the electrically conductive polymer layer is included within the gas diffusion layer.

18. The apparatus of claim 14 , wherein the electrically conductive polymer layer is operable to limit the transfer of the fuel reactant into the catalyst to a rate that is at least five times less than a rate that the fuel reactant is able to transfer across the gas diffusion layer.

19. The apparatus of claim 14 , wherein the electrically conductive polymer layer is operable to limit the transfer of the fuel reactant into the catalyst to a rate that is equal to, substantially equal to, or not substantially greater than, a given consumption rate of the fuel reactant at the catalyst.

20. The apparatus of claim 14 , wherein the polymer electrolyte membrane comprises one of a proton exchange membrane and an alkaline exchange membrane.

21. The apparatus of claim 14 , wherein the fuel reactant comprises one of an alkanol having from one to six carbons and an alkane having from one to six carbons.

Assignees

• Stanis Ronald J
• Lambert Timothy N
• Sandia Corp

Inventors

• Stanis Ronald J
• Lambert Timothy N

Classifications

• H01M8/08 Primary

  Fuel cells with aqueous electrolytes · CPC title

• H01M8/1011 Primary

  Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC] · CPC title

• H01M8/0239

  Organic resins; Organic polymers · CPC title

• H01M8/0245

  in the form of layered or coated products · CPC title

• H01M8/0234

  Carbonaceous material · CPC title