# US 8,465,632 B2 · Thin film catalyst on porous media and electrochemical cell employing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,465,632 B2 - Document ID: US8465632B2 - Status: Granted - Kind: B2 - Application number: 12/981,596 - Filed: 2010-12-30 - Published: 2011-06-16 - Granted: 2013-06-18 - Earliest claimed: 2010-12-30 - Assignees: Ford Global Technologies, LLC - Applicants: Alireza Pezhman Shirvanian - Inventors: Alireza Pezhman Shirvanian - Web page: https://patentgrep.com/patent/US8465632B2 ## CPC - H01M 4/92: Metals of platinum group (H01M4/94 {, H01M4/9058} take precedence) - H01M 4/861: {with a gradient in the porosity} - H01M 4/8807: {Gas diffusion layers} - H01M 4/925: {supported on carriers, e.g. powder carriers} - Y02E 60/50: Fuel cells - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract In one embodiment, a catalyst assembly includes a porous substrate material including a substrate bulk and an external surface, the substrate bulk including a network of pores for diffusing fluids there-through, and a two dimension (2-D) extensive catalyst supported on at least a portion of the network of pores to provide a substantially constant catalyst concentration profile along a thickness dimension of the substrate bulk. In certain instances, the network of pores includes an internal pore surface for supporting at least a portion of the 2-D extensive catalyst. ## Claims ### Claim 1 A catalyst assembly comprising: a porous substrate material including an external surface and a substrate bulk including a network of diffusive pores and first and second substrate layers respectively having first and second average pore sizes different from one another; and a two dimensional extensive catalyst supported on at least a portion of the network of diffusive pores to provide a substantially constant catalyst concentration profile along a thickness of the substrate bulk. ### Claim 2 (depends on 1) The catalyst assembly of claim 1, wherein the network of diffusive pores includes an internal pore surface supporting at least a portion of the two dimensional extensive catalyst. ### Claim 3 (depends on 1) The catalyst assembly of claim 1, wherein the two dimensional extensive catalyst has a thickness dimension of 1 to 50 atomic layers. ### Claim 4 (depends on 1) The catalyst assembly of claim 1, wherein the porous substrate material is electronically conductive. ### Claim 5 (depends on 1) The catalyst assembly of claim 1, further comprising a volume of electrolyte adjacent the porous substrate material, the volume of electrolyte including a solvent content of no greater than 5 percent by weight. ### Claim 6 (depends on 1) The catalyst assembly of claim 1, wherein the substrate bulk further includes a third substrate layer disposed next to the second substrate layer and having a third average pore size, the second substrate being positioned between the first and the third substrate layers. ### Claim 7 (depends on 6) The catalyst assembly of claim 6, wherein the first average pore size is smaller than the second average pore size, and the second average pore size is smaller than the third average pore size. ### Claim 8 (depends on 1) The catalyst assembly of claim 1, wherein the two dimensional extensive catalyst contacts one or more pores of both the first and second substrate layers. ### Claim 9 (depends on 2) The catalyst assembly of claim 2, wherein the two dimensional extensive catalyst includes two or more spaced apart catalyst patches each contacting the internal pore surface. ### Claim 10 (depends on 1) The catalyst assembly of claim 1, wherein the substrate bulk further includes a plurality of wires extending longitudinally from an internal pore surface. ### Claim 11 (depends on 10) The catalyst assembly of claim 10, wherein the two dimensional extensive catalyst contacts at least a portion of the plurality of wires. ### Claim 12 A catalyst assembly comprising: a porous substrate material including an external surface and a substrate bulk including a network of diffusive pores and a plurality of wires extending longitudinally from an internal pore surface of the network of diffusive pores; and a two dimensional extensive catalyst supported on at least a portion of the network of diffusive pores to provide a substantially constant catalyst concentration profile along a thickness of the substrate bulk. ### Claim 13 (depends on 12) The catalyst assembly of claim 12, wherein the two dimensional extensive catalyst has a thickness dimension of 1 to 50 atomic layers. ### Claim 14 (depends on 12) The catalyst assembly of claim 12, wherein the porous substrate material is electronically conductive. ### Claim 15 (depends on 12) The catalyst assembly of claim 12, wherein the substrate bulk further includes first and second substrate layers respectively having first and second average pore sizes, the first average pore size being smaller than the second average pore size. ### Claim 16 (depends on 15) The catalyst assembly of claim 15, wherein the two dimensional extensive catalyst contacts one or more pores of both the first and second substrate layers. ### Claim 17 (depends on 12) The catalyst assembly of claim 12, wherein the two dimensional extensive catalyst contacts at least a portion of the plurality of wires. ### Claim 18 An electrochemical cell comprising: a catalyst assembly including a porous substrate material including a substrate bulk and an external surface, the substrate bulk including a network of diffusive pores and a plurality of wires extending longitudinally from an internal pore surface of the network of diffusive pores; a two dimensional extensive catalyst supported on at least a portion of the network of diffusive pores to provide a substantially constant catalyst concentration profile along a thickness of the substrate bulk; and a volume of electrolyte positioned next to the catalyst assembly and having a solvent content of no greater than 5 percent by weight. ### Claim 19 (depends on 18) The electrochemical cell of claim 18, wherein the porous substrate material is electronically conductive.