Fabrication of membrane electrode assembly with filament extension atomizer spray
AssigneeXerox Corporation
InventorsElif Karatay, Kathryn F. Murphy
Life of this patent
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Abstract
A method and apparatus are described for forming a multilayer assembly. The method includes adhering first and second catalyst layers to opposed sides of a polymer membrane. At least one of the first catalyst layer, the second catalyst layer, and the polymer membrane is formed by filament extension atomization of a fluid material to form atomized droplets that are sprayed to form the respective membrane or layer.
Claims15
A method for forming a multilayer assembly comprising:
- providing a first catalyst layer in contact with a first side of a polymer membrane, the first catalyst layer being formed from a first layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer, the first layer-forming material further comprising at least one solvent, wherein a total solvent is no more than 10 wt. % of the first layer-forming material;
- providing a second catalyst layer in contact with an opposed second side of the polymer membrane, the second catalyst layer being formed from the first layer-forming material or from a second layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer;
- wherein at least one of the first catalyst layer, the second catalyst layer, and the polymer membrane is formed by filament extension atomization of a fluid material to form atomized droplets that are sprayed to form the respective membrane or layer.
A method for forming a multilayer assembly comprising:
- providing a first catalyst layer in contact with a first side of a polymer membrane, the first catalyst layer being formed from a first layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer;
- providing a second catalyst layer in contact with an opposed second side of the polymer membrane, the second catalyst layer being formed from the first layer-forming material or from a second layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer;
- wherein the polymer membrane is formed by filament extension atomization of a membrane-forming material to form atomized droplets that are sprayed on at least one of the first and second catalyst layers, the membrane-forming material comprising a molten thermoset polymer.
A method for forming a multilayer assembly the multilayer comprising first and second microporous layers, a polymer membrane, a first catalyst layer in contact with a first side of the polymer membrane and a second catalyst layer in contact with a second side of the polymer membrane, the method comprising:
- spraying atomized droplets formed by filament extension atomization of a first layer-forming material to form a first catalyst layer on one of the first microporous layer and the first side of the polymer membrane, the first layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer, the first layer-forming material comprising no more than 10 wt. % of solvent;
- and
- spraying atomized droplets formed by filament extension atomization of a second layer-forming material to form the second catalyst layer on one of the second microporous layer and the second side of a polymer membrane, the second layer-forming material comprising a polymer and catalyst particles, dispersed in the polymer, the second layer-forming material comprising no more than 10 wt. % of solvent.
Dependencies are inferred from the claim text.