# US 11,444,287 B2 · Catalyst complex for fuel cells and a method for manufacturing an electrode including the same

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- Number: US 11,444,287 B2
- Document ID: US11444287B2
- Status: Granted
- Kind: B2
- Application number: 17/039,037
- Filed: 2020-09-30
- Published: 2021-05-06
- Granted: 2022-09-13
- Earliest claimed: 2019-10-31
- Assignees: Hyundai Motor Company; Kia Motors Corporation
- Applicants: Hyundai Motor Company; Kia Motors Corporation
- Inventors: Jongkil Oh; Bo Ki Hong
- Web page: https://patentgrep.com/patent/US11444287B2

## CPC

- H01M 4/8652: {as mixture}
- H01M 8/1018: Polymeric electrolyte materials
- H01M 4/8657: {layered}
- H01M 4/8668: {Binders}
- H01M 4/8828: {Coating with slurry or ink}
- H01M 4/8882: {Heat treatment, e.g. drying, baking}
- H01M 4/9041: {Metals or alloys (H01M4/92 takes precedence)}
- H01M 4/9075: {Catalytic material supported on carriers, e.g. powder carriers (H01M4/8807, H01M4/881, H01M4/8814, H01M4/925 take precedence)}
- H01M 4/9083: {on carbon or graphite}
- H01M 4/926: {on carbon or graphite}
- H01M 8/0656: by electrochemical means (H01M8/065 takes precedence)
- H01M 4/9058: {of noble metals or noble-metal based alloys}
- H01M 2250/20: Fuel cells in motive systems, e.g. vehicle, ship, plane
- Y02E 60/50: Fuel cells
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A catalyst complex for fuel cells and a method for manufacturing an electrode including the same are disclosed. The catalyst complex for fuel cells, which is included in an electrode for fuel cells, includes a first catalyst configured to cause hydrogen oxidation reaction (HOR) and a second catalyst configured to cause water electrolysis reaction, i.e., oxygen evolution reaction (OER). The outer surface of the first catalyst is coated with a first ionomer binder, the outer surface of the second catalyst is coated with a second ionomer binder, and an equivalent weight (EW) of the second ionomer binder differs from an equivalent weight (EW) of the first ionomer binder.

## Claims

### Claim 1

A catalyst complex for fuel cells, the catalyst complex being included in an electrode for fuel cells, the catalyst complex for fuel cells comprising:
a first catalyst configured to cause hydrogen oxidation reaction; and
a second catalyst configured to cause water electrolysis reaction with the first catalyst,
wherein an outer surface of the first catalyst is coated with a first ionomer binder and an outer surface of the second catalyst is coated with a second ionomer binder,
wherein an equivalent weight (EW) of the second ionomer binder differs from an equivalent weight (EW) of the first ionomer binder,
wherein the first catalyst comprises a metal catalyst, and
wherein the second catalyst comprises a metal oxide.

### Claim 2 (depends on 1)

The catalyst complex for fuel cells of claim 1, wherein the equivalent weight (EW) of the second ionomer binder is 92% or less of the equivalent weight (EW) of the first ionomer binder.

### Claim 3 (depends on 1)

The catalyst complex for fuel cells of claim 1, wherein the equivalent weight (EW) of the first ionomer binder is 700 to 1200.

### Claim 4 (depends on 1)

The catalyst complex for fuel cells of claim 1, wherein the first catalyst comprises a supported-type catalyst in which catalyst particles are supported on a carbon support, and
wherein the carbon support comprises one selected from a group comprising carbon black (CB), carbon nanotubes (CNTs), carbon nanofibers (CNFs), carbon nanowires (CNWs), carbon nanohorns (CNHs), graphene, and combinations thereof.

### Claim 5 (depends on 1)

The catalyst complex for fuel cells of claim 1,
wherein the metal catalyst comprises one selected from a group comprising platinum (Pt), palladium (Pd), ruthenium (Ru), iridium (Ir), gold (Au), silver (Ag), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), molybdenum (Mo), yttrium (Y), and combinations thereof, and
wherein the metal oxide comprises one selected from a group comprising ruthenium (Ru), iridium (Ir), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), molybdenum (Mo), yttrium (Y), and combinations thereof.

### Claim 6 (depends on 1)

The catalyst complex for fuel cells of claim 1, wherein the second catalyst comprises a supported-type catalyst in which catalyst particles are supported on a support.

### Claim 7 (depends on 6)

The catalyst complex for fuel cells of claim 6, wherein the support comprises one selected from a group comprising carbon black, carbon nanotubes, carbon nanofibers, carbon nanowires, carbon nanohorns, graphene, titanium oxide, cerium oxide, niobium oxide, tungsten oxide, titanium carbide, titanium nitride, and combinations thereof.

### Claim 8 (depends on 1)

The catalyst complex for fuel cells of claim 1, wherein a content of the second catalyst is 2 wt % to 80 wt % with respect to a weight of the first catalyst.

### Claim 9

A method for manufacturing an electrode for fuel cells including a catalyst complex, the method comprising:
preparing a first coated catalyst by coating a first catalyst with a first ionomer binder;
preparing a second coated catalyst by coating a second catalyst with a second ionomer binder having an equivalent weight (EW) which is 92% or less of an equivalent weight (EW) of the first ionomer binder;
preparing a catalyst ink by mixing the first coated catalyst, the second coated catalyst and a solvent; and
manufacturing the electrode using the catalyst ink,
wherein the first catalyst comprises a metal catalyst, and
wherein the second catalyst comprises a metal oxide.

### Claim 10 (depends on 9)

The method of claim 9, wherein, in the preparing the catalyst ink, the solvent comprises at least one of alcohol or deionized water, and
wherein the alcohol comprises one selected from a group comprising isopropyl alcohol (IPA), n-propyl alcohol (nPA), ethyl alcohol, and combinations thereof.

### Claim 11 (depends on 9)

The method of claim 9, wherein the second catalyst in the catalyst ink has a content of 2 wt % to 80 wt % with respect to a weight of the first catalyst.

### Claim 12 (depends on 9)

The method of claim 9, wherein the preparing the first coated catalyst comprises:
preparing a first mixed solution comprising the first catalyst, the first ionomer binder, and a first solvent; and
performing drying and heat treatment of the first mixed solution.

### Claim 13 (depends on 12)

The method of claim 12, wherein the first ionomer binder in the first mixed solution has a content of 10 wt % to 50 wt % with respect to a total weight of the first catalyst and the first ionomer binder.

### Claim 14 (depends on 12)

The method of claim 12, wherein, in the performing the heat treatment of the first mixed solution, the heat treatment is performed within a range of an α-transition temperature of the first ionomer binder to a temperature higher than the α-transition temperature by 100° C.

### Claim 15 (depends on 12)

The method of claim 12, wherein, in the performing the heat treatment of the first mixed solution, the heat treatment is performed for 10 minutes to 10 hours.

### Claim 16 (depends on 9)

The method of claim 9, wherein the preparing the second coated catalyst comprises:
preparing a second mixed solution comprising the second catalyst, the second ionomer binder, and a second solvent; and
performing drying and heat treatment of the second mixed solution.

### Claim 17 (depends on 16)

The method of claim 16, wherein the second ionomer binder in the second mixed solution has a content of 5 wt % to 40 wt % with respect to a total weight of the second catalyst and the second ionomer binder.

### Claim 18 (depends on 16)

The method of claim 16, wherein, in the performing the heat treatment of the second mixed solution, the heat treatment is performed within a range of an α-transition temperature of the second ionomer binder to a temperature higher than the α-transition temperature by 100° C.

### Claim 19 (depends on 16)

The method of claim 16, wherein, in the performing the heat treatment of the second mixed solution, the heat treatment is performed for 10 minutes to 10 hours.

### Claim 20

A method for manufacturing an electrode for fuel cells including a catalyst complex, the method comprising:
preparing a first mixed solution comprising a first catalyst, a first ionomer binder, and a first solvent;
preparing a second mixed solution comprising a second catalyst, a second ionomer binder, and a second solvent;
preparing a second coated catalyst by performing drying and heat treatment of the second mixed solution;
preparing a catalyst ink by mixing the first mixed solution and the second coated catalyst; and
manufacturing the electrode using the catalyst ink,
wherein the first catalyst comprises a metal catalyst, and
wherein the second catalyst comprises a metal oxide.