Gas diffusion electrode producing method for e.g. low temperature polymer electrolyte membrane fuel cell for motor vehicle, involves attaching layer with thickness less than preset value, to another layer

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method for producing a gas diffusion electrode for fuel cells, particularly polymer electrolyte membrane (PEM) fuel cells. The core idea is to construct a catalyst layer with a two-layer structure: a very thin, highly catalyst-loaded layer (e.g., densely packed platinum particles) in direct contact with the polymer membrane, and a much thicker, but very lightly catalyst-loaded layer atop a gas diffusion substrate. This configuration optimizes catalytic efficiency while reducing the overall amount of expensive catalyst used, thereby lowering costs and improving performance.

Use CasesContent extracted from patent full text and abstract with AI.

• Low-temperature polymer electrolyte membrane (PEM) fuel cells for automotive and transportation applications
• Direct methanol fuel cells for portable or stationary power supplies
• High-temperature PEM fuel cells for industrial or backup power systems
• Fuel cell stacks in electric vehicles and hybrid vehicles
• Stationary energy generation using fuel cells for clean energy

BenefitsContent extracted from patent full text and abstract with AI.

• Reduces use of expensive noble metal catalysts (such as platinum), significantly lowering production costs of fuel cells.
• Improves catalytic activity at the membrane interface, increasing fuel cell efficiency and power output.
• Minimizes voltage loss and enhances current distribution across the electrode, leading to better overall cell performance.
• Allows for more flexible manufacturing by decoupling catalyst loading from the total thickness, enabling tailored electrode designs for specific applications.
• Can be applied to various types of fuel cells, including low-temperature and high-temperature PEM cells, enhancing their commercial viability.

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Patent Abstract

The method involves applying a layer with a thickness greater than 5 micrometers and a catalyst material charge of less than 0.1 milligram per square centimeter on a gas diffusion layer. The layer is loaded with catalyst e.g. platinum particles. Another layer with a thickness less than 5 micrometer and catalyst material charge of greater than 1 milligram per square centimeter is attached to the former layer. The latter layer is loaded with the catalyst and is applied on a polymer membrane. The gas diffusion layer is pressed on the membrane. An independent claim is also included for a gas diffusion electrode comprising layers.