# US 2018/0026273 A1 · Method and device for modifying catalyst layer

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- Number: US 2018/0026273 A1
- Document ID: US20180026273A1
- Status: Published application
- Kind: A1
- Application number: 15/546,687
- Filed: 2015-02-02
- Published: 2018-01-25
- Earliest claimed: 2015-02-02
- Assignees: Nissan Motor Co., Ltd.
- Applicants: Nissan Motor Co., Ltd.
- Inventors: Hiroshi OKONOGI; Aurel FUNAR; Yasuhiro NUMAO; Tooru KOSEMURA; Takayuki HIRAO; Kimio NISHIMURA
- Web page: https://patentgrep.com/patent/US20180026273A1

## CPC

- H01M 4/8878: {Treatment steps after deposition of the catalytic active composition or after shaping of the electrode being free-standing body}
- B05B 5/025: Discharge apparatus, e.g. electrostatic spray guns
- B05C 5/00: Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work (B05C7/00 takes precedence; essentially involving spraying or electrostatic projection B05B)
- B05C 11/00: Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00 (means for manipulating or holding work B05C13/00; enclosures for apparatus, booths B05C15/00; spray booths B05B16/00)
- B32B 37/025: {Transfer laminating}
- B32B 43/00: Operations specially adapted for layered products and not otherwise provided for, e.g. repairing; Apparatus therefor
- H01M 4/8814: {Temporary supports, e.g. decal}
- H01M 4/8832: {Ink jet printing}
- B29C 65/526: {by printing or by transfer from the surfaces of elements carrying the adhesive, e.g. using brushes, pads, rollers, stencils or silk screens}
- B29C 66/0346: {Cutting or perforating, e.g. burning away by using a laser or using hot air (simultaneously joining and severing using a fluid B29C65/7471; simultaneously welding and severing using radiation B29C65/7473)}
- B29C 73/025: {fed under pressure}
- B32B 2457/18: Fuel cells
- H01M 4/8828: {Coating with slurry or ink}
- H01M 8/1018: Polymeric electrolyte materials
- Y02E 60/50: Fuel cells
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- 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)
- B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method is provided that modifies a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane. In the catalyst layer correction method, presence or absence of a defect in the catalyst layer is detected. The defect is removed based on the size and position of the detected defect. The portion from which the defect has been removed is repaired by application thereto of a correcting ink corresponding to the catalyst layer.

## Claims

### Claim 1

A catalyst layer correction method for modifying a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, comprising:
detecting the presence or absence of a defect in the catalyst layer after a catalyst ink that is coated on the transfer sheet has been dried and the catalyst layer has been formed,
removing the defect based on size and position of the defect that is detected,
transferring the catalyst layer onto the electrolyte membrane and peeling off the transfer sheet from the catalyst layer, after which and
repairing the defect by applying a correcting ink corresponding to the catalyst layer to a portion from which the defect has been removed.

### Claim 2

(canceled)

### Claim 3 (depends on 1)

The catalyst layer correction method according to claim 1, wherein
the correcting ink is applied with an inkjet system.

### Claim 4 (depends on 3)

The catalyst layer correction method according to claim 3, wherein
the inkjet system is one of a piezo inkjet system, a continuous inkjet system, an electrostatic inkjet system, and a valve inkjet system.

### Claim 5 (depends on 1)

The catalyst layer correction method according to claim 1, wherein
the defect is removed by irradiating laser light on the defect.

### Claim 6 (depends on 1)

The catalyst layer correction method according to claim 1, wherein
the defect is removed by apply onto the catalyst layer a solvent that dissolves the catalyst layer that is disposed around the defect.

### Claim 7 (depends on 6)

The catalyst layer correction method according to claim 6, wherein
the solvent is applied with an inkjet system, and the applying of the correcting ink is applied with a coating unit that is used to apply the solvent.

### Claim 8 (depends on 1)

The catalyst layer correction method according to claim 1, wherein
again detecting the presence or absence of a defect in the catalyst layer after removal of the defect and before repair by application of the correcting ink.

### Claim 9 (depends on 1)

The catalyst layer correction method according to claim 1, wherein
the removing of the defect up to a surface of the transfer sheet on a side on which the catalyst layer is formed.

### Claim 10 (depends on 1)

The catalyst layer correction method according to claim 1, further comprising
inspecting the quality of the repair of the catalyst layer after repair by application of the correcting ink.

### Claim 11

A catalyst layer correction device for modifying a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, the catalyst layer correction device comprising:
a detection unit that detects a presence or absence of a defect in the catalyst layer;
a removal unit that removes the defect based on size and position of the defect detected by the detection unit; and
a repair unit that repairs a portion from which the defect has been removed through application thereto of a correcting ink corresponding to the catalyst layer.
the detection unit is configured to detect the presence or absence of the defect in the catalyst layer, which is formed after a catalyst ink that is coated on the transfer sheet has dried, and
the repair unit is configured to repair the portion of the catalyst layer from which the defect has been removed by applying thereto the correcting ink, after the catalyst layer has been transferred onto the electrolyte membrane and the transfer sheet has been peeled off.

### Claim 12

(canceled)

### Claim 13 (depends on 11)

The catalyst layer correction device according to claim 11, wherein
the repair unit includes an inkjet system that applies the correcting ink.

### Claim 14 (depends on 13)

The catalyst layer correction device according to claim 13, wherein
the inkjet system is one of a piezo inkjet system, a continuous inkjet system, an electrostatic inkjet system and a valve inkjet system.

### Claim 15 (depends on 11)

The catalyst layer correction device according to claim 11, wherein
the removal unit includes a laser configured to remove the defect by irradiating laser light on the defect.

### Claim 16 (depends on 11)

The catalyst layer correction device according to claim 11, wherein
the removal unit is configured to remove the defect by application onto the catalyst layer a solvent that dissolves the catalyst layer that is disposed on the periphery of the defect.

### Claim 17 (depends on 16)

The catalyst layer correction device according to claim 16, wherein
the removal unit is configured to apply the solvent with an inkjet system, and
the repair unit is configured to apply the correcting ink using a coating unit that applies the solvent.

### Claim 18 (depends on 11)

The catalyst layer correction device according to claim 11, wherein
the detection unit is configured to again detects the presence or absence of a defect in the catalyst layer from which the defect has been removed.

### Claim 19 (depends on 11)

The catalyst layer correction device according to claim 11, wherein
the removal unit is configured to effect removal up to a surface of the transfer sheet on a side on which the catalyst layer is formed.

### Claim 20 (depends on 11)

The catalyst layer correction device according to claim 11, further comprising
an inspection unit that inspects the quality of the repair of the catalyst layer after repair by application of the correcting ink.

### Claim 21

A catalyst layer correction method that modifies a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, comprising:
detecting the presence or absence of a defect in the catalyst layer,
removing the defect based on size and position of the detected defect, and
repairing the defect by applying a correcting ink corresponding to the catalyst layer with an inkjet system to a portion from which the defect has been removed.

### Claim 22

A catalyst layer correction method for modifying a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, comprising:
detecting the presence or absence of a defect in the catalyst layer,
removing the defect by irradiating a laser based on size and position of the defect that is detected, and
repairing the defect by applying a correcting ink corresponding to the catalyst layer to a portion from which the defect has been removed.

### Claim 23

A catalyst layer correction method for modifying a catalyst layer of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, comprising:
presence or absence of a defect in the catalyst layer is detected,
removing the defect by applying a solvent onto the catalyst layer to dissolve the catalyst layer that is disposed around the defect based on size and position of the defect that is detected, and
repairing the defect by applying a correcting ink corresponding to the catalyst layer to a portion from which the defect has been removed.

### Claim 24

A catalyst layer correction catalyst layer correction device of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, the catalyst layer correction device comprising:
a detection unit that detects presence or absence of a defect in the catalyst layer,
a removal unit that removes the defect based on size and position of the defect detected by the detection unit, and
a repairing unit that repairs a portion from which the defect has been removed by the removal unit by applying a correcting ink corresponding to the catalyst layer thereon, wherein
the repairing unit applies the correcting ink by an inkjet system.

### Claim 25

A catalyst layer correction catalyst layer correction device of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, the catalyst layer correction device comprising:
a detection unit that detects presence or absence of a defect in the catalyst layer,
a removal unit that removes the defect based on size and position of the defect detected by the detection unit, and
a repairing unit that repairs a portion from which the defect has been removed by the removal unit by applying a correcting ink corresponding to the catalyst layer thereon,
the removal unit including a laser that is configured to removes the defect by irradiating laser light on the defect.

### Claim 26

A catalyst layer correction catalyst layer correction device of a membrane catalyst layer assembly, which is manufactured by transferring the catalyst layer formed on a transfer sheet onto an electrolyte membrane, the catalyst layer correction device comprising:
a detection unit that detects presence or absence of a defect in the catalyst layer,
a removal unit that removes the defect based on size and position of the defect detected by the detection unit, and
a repairing unit that repairs a portion from which the defect has been removed by the removal unit by applying a correcting ink corresponding to the catalyst layer thereon,
the removal unit removes the defect by applying a solvent onto the catalyst layer to dissolve the catalyst layer that is disposed around the defect.