# US 11,909,052 B2 · Fabrication of membrane electrode assembly with filament extension atomizer spray > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,909,052 B2 - Document ID: US11909052B2 - Status: Granted - Kind: B2 - Application number: 17/364,163 - Filed: 2021-06-30 - Published: 2023-01-05 - Granted: 2024-02-20 - Earliest claimed: 2021-06-30 - Assignees: Xerox Corporation - Applicants: Palo Alto Research Center Incorporated - Inventors: Elif Karatay; Kathryn F. Murphy - Web page: https://patentgrep.com/patent/US11909052B2 ## CPC - H01M 4/8825: {Methods for deposition of the catalytic active composition} - B05B 3/04: driven by the liquid or other fluent material discharged, e.g. the liquid actuating a motor before passing to the outlet - H01M 4/8642: {Gradient in composition} - H01M 4/8807: {Gas diffusion layers} - H01M 4/881: {Electrolytic membranes} - H01M 8/1004: characterised by membrane-electrode assemblies [MEA] (H01M8/12 takes precedence) - H01M 8/1081: starting from solutions, dispersions or slurries exclusively of polymers - H01M 4/886: {Powder spraying, e.g. wet or dry powder spraying, plasma spraying} - H01M 2008/1095: {Fuel cells with polymeric electrolytes} - Y02E 60/50: Fuel cells - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D) - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The method of claim 1, wherein the total solvent is no more than 5 wt. % of the first layer-forming material. ### Claim 3 (depends on 1) The method of claim 1, wherein the first layer-forming material is sprayed onto one of the membrane and a microporous layer. ### Claim 4 (depends on 1) The method of claim 1, wherein the first catalyst layer comprises at least two sub-layers of a controllable thickness, a first of the sublayers having a higher concentration of the catalyst particles than a second of the sublayers. ### Claim 5 (depends on 1) The method of claim 1, further comprising varying a concentration of catalyst particles in the first catalyst layer in a direction parallel to a thickness of the membrane. ### Claim 6 (depends on 1) The method of claim 1, further comprising varying a concentration of catalyst particles in the first catalyst layer in a direction perpendicular to a thickness of the membrane. ### Claim 7 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. ### Claim 8 (depends on 1) The method of claim 1, wherein an interface between the first catalyst layer and the membrane is non-planar. ### Claim 9 (depends on 1) The method of claim 1, further comprising adhering the first catalyst layer to a first microporous layer and adhering the second catalyst layer to a second microporous layer. ### Claim 10 (depends on 9) The method of claim 9, further comprising coating the first microporous layer with a fluoropolymer layer formed by filament extension atomization of a fluid fluoropolymer material prior to adhering the first catalyst layer to a first microporous layer. ### Claim 11 (depends on 1) The method of claim 1, wherein the polymer membrane is proton-permeable. ### Claim 12 (depends on 1) The method of claim 1, further comprising incorporating the multilayer assembly into a membrane electrode assembly, the membrane electrode assembly comprising first and second electrodes spaced by the multilayer assembly. ### Claim 13 (depends on 1) The method of claim 1, wherein: the filament extension atomization of the first catalyst layer forming material is performed with a first filament extension atomizer which generates an aerosol from the first catalyst layer forming material in fluid form, by stretching the fluid material in a nip defined between rotating rollers; and forming the first catalyst layer with a first applying station which receives the aerosol, the first applying station including outlets which deposit droplets of the aerosol on a substrate to form the first catalyst layer, the substrate comprising one of a microporous layer and the polymer membrane; the first applying station, or a second applying station, applying the other of the microporous layer and the polymer membrane to the first catalyst layer. ### Claim 14 (depends on 1) The method of claim 1, wherein: the polymer and catalyst particles comprise at least 20 wt. % of the first catalyst layer material; the method further comprising: adhering a first microporous layer to the first catalyst layer; and curing the first catalyst layer material. ### Claim 15 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.