Roll-to-roll fabrication of high performance fuel cell electrode with core-shell catalyst using seeded electrodes
AssigneeGM Global Technology Operations LLC
InventorsAnusorn Kongkanand, Yun Cai
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Abstract
A method for forming a fuel cell catalyst includes a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are formed on the carbon particles. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium to form palladium-coated particles. The palladium-coated particles include a palladium shell covering the tungsten-nickel alloy particles. The palladium-coated particles are coated with platinum to form an electrode layer including core shell catalysts distributed therein.
Claims20
A method for forming a fuel cell catalyst, the method comprising:
- a) forming an ionomer-containing layer including carbon particles and an ionomer;
- b) forming tungsten-nickel alloy particles on the carbon particles;
- c) replacing at least a portion of the nickel in the tungsten-nickel alloy particles with palladium to form palladium-coated particles, the palladium-coated particles having a palladium shell covering the tungsten-nickel alloy particles;
- and
- d) coating the palladium-coated particles with platinum to form an electrode layer including core shell catalysts distributed therein.
A method for forming a fuel cell catalyst, the method comprising:
- a) forming an ionomer-containing layer including carbon particles and an ionomer;
- b) electrochemically forming tungsten-nickel alloy particles on the carbon particles from a solution including a nickel-containing salt and a tungsten-containing salt;
- c) replacing at least a portion of the nickel in the tungsten-nickel alloy particles with palladium by a galvanic displacement reaction in which the tungsten-nickel alloy particles are contacted with a palladium-containing solution to form palladium-coated particles;
- and
- d) coating the palladium-coated particles with platinum to form an electrode layer including core shell catalysts distributed therein wherein the palladium-coated particles are coated with platinum by depositing copper on the palladium-coated particles and then replacing at least a portion of the copper with platinum.
Dependencies are inferred from the claim text.