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US 2022/0013790 A1Published application
Catalyst layers of membrane-electrode assemblies and methods of making same
AssigneeNikola Corporation
InventorJohn Slack
Life of this patent
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Abstract
Improved catalyst layers for use in fuel cell membrane electrode assemblies, and methods for making such catalyst layers, are provided. Catalyst layers can comprise structured units of catalyst, catalyst support, and ionomer. The structured units can provide for more efficient electrical energy production and/or increased lifespan of fuel cells utilizing such membrane electrode assemblies. Catalyst layers can be directly deposited on exchange membranes, such as proton exchange membranes.
Claims20
A method of forming an electrode, the method comprising:
- providing a first reservoir containing a first dispersion, wherein the first dispersion comprises an ionomer, a carbon-containing catalyst powder, and a first solvent;
- providing a second reservoir containing a second dispersion, wherein the second dispersion comprises the ionomer and a second solvent;
- applying an electrical bias between a substrate and a first needle in fluid communication with the first reservoir;
- and
- pumping the first dispersion from the first reservoir through the first needle towards a first surface of the substrate and pumping the second dispersion from the second reservoir through the first needle towards the surface of the substrate to form a plurality of structured units on a surface of the substrate,
- wherein each of the structured units comprise a spherical inner core having a first radius and a spherical outer shell having a second radius greater than the first radius and concentrically surrounding the inner core, and
- wherein the outer shell comprises the ionomer at a first concentration and the inner shell comprises the ionomer at a second concentration that is greater than the first concentration.
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A method of forming an electrode, comprising:
- providing to a first reservoir a first dispersion comprising a plurality of catalyst particles, a surfactant, a first solvent, and water;
- providing to a second reservoir a second dispersion comprising an ionomer and a second solvent;
- applying an electrical bias between the substrate and a first needle in fluid communication with the first reservoir and a second needle in fluid communication with the second reservoir;
- pumping the first dispersion through the first needle towards a surface of a substrate;
- and
- pumping the second dispersion through the second needle towards the surface of the substrate.
3 more elements
Dependencies are inferred from the claim text.