Method of producing membrane electrode assemblies for use in proton exchange membrane and direct methanol fuel cells
AssigneeCabot Corporation
InventorsMark J. Hampden-Smith, Toivo T. Kodas, Paolina Atanassova, Rimple Bhatia, Ross A. Miesem, Paul Napolitano, Gordon L. Rice
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Abstract
Compositions and methods for the manufacture of electrodes for fuel cells. The compositions and methods are particularly useful for the manufacture of anodes and cathodes for proton exchange membrane fuel cells, particularly direct methanol fuel cells. The methods can utilize direct-write tools to deposit ink compositions and form functional layers of a membrane electrode assembly having controlled properties and enhanced performance.
Claims26
A method for the manufacture of an electrode for a fuel cell, comprising the steps of:
- a) depositing a first ink composition on at least a portion of a substrate to form a first material layer, said first ink composition comprising at least a first material selected from the group consisting of a proton conducting polymer and a hydrophobic material;
- b) depositing a second ink composition on at least a portion of said first material layer, wherein said second ink composition comprises at least said first material in a concentration that is different than the concentration of said first material in said first ink composition.
A method for the fabrication of an electrode for a direct methanol fuel cell, comprising the steps of:
- a) providing a proton exchange membrane;
- b) depositing a first ink composition comprising first electrocatalyst particles on said proton exchange membrane using a direct-write tool to form a first electrocatalyst layer;
- c) depositing a second ink composition comprising second electrocatalyst particles on at least a portion of said first electrocatalyst layer, wherein said second electrocatalyst particles have an average particle size that is larger than said first electrocatalyst particles;
- and
- d) attaching a fluid distribution layer over said second electrocatalyst layer.
A method for making an electrode for a direct methanol fuel cell, comprising the steps of:
- a) providing a proton exchange membrane;
- b) depositing a first ink composition comprising first electrocatalyst particles on first regions of said proton exchange membrane to form a first electrocatalyst layer, said first electrocatalyst particles having an average aggregate particle size of not greater than about 10 μm;
- c) depositing a second ink composition comprising second electrocatalyst particles on second regions of said proton exchange membrane to form a second electrocatalyst layer, wherein said second electrocatalyst particles have an average aggregate particle size that is larger than said first electrocatalyst particles and is not greater than about 200 μm;
- and
- d) depositing a fluid distribution layer over said first and second electrocatalyst layers.
A method for the manufacture of an electrode for a fuel cell, comprising the steps of:
- a) depositing a first ink composition on at least a portion of a substrate to form a first material layer, said first ink composition comprising first electrocatalyst particles;
- b) depositing a second ink composition on at least a portion of said first material layer, wherein said second ink composition comprises second electrocatalyst particles in a concentration that is different than the concentration of said first electrocatalyst particles in said first ink composition, and wherein said second electrocatalyst particles have an average particle size that is different than said first electrocatalyst particles;
- wherein at least one of said depositing steps comprises depositing the first or second ink composition with a direct-write tool.
Dependencies are inferred from the claim text.