Gas Diffusion Body

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This invention relates to a gas diffusion body used in electrochemical cells (such as electrolysis or fuel cells). The innovation is a multi-layer structure where a base layer made from electrically conductive expanded metal, mesh, or perforated metal is coated with one or more additional porous layers made up of electrically conductive metal particles (mainly titanium, possibly with platinum, gold, or iridium additives), applied via a thermal spraying process. This approach enables precise control over porosity and layer structure, improving performance and mechanical stability compared to traditional sintered or laminated alternatives.

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

• Proton exchange membrane (PEM) electrolyzers for hydrogen and oxygen production via water electrolysis.
• Fuel cells (e.g., hydrogen fuel cells) requiring robust, conductive, and optimized gas diffusion layers.
• Industrial electrochemical processes (e.g., chlorine-alkali electrolysis, metal plating) where optimized gas/liquid transport and mechanical stability are important.
• Electrolyzers in renewable energy systems for hydrogen generation and energy storage.
• Advanced battery technologies or supercapacitors that use gas diffusion layers in their design.

BenefitsContent extracted from patent full text and abstract with AI.

• Precise and reproducible control over pore size and geometry for optimal gas and liquid transport.
• Enhanced mechanical stability, reducing membrane damage and improving device durability under pressure or dynamic operation.
• Shorter and more scalable production cycles due to high deposition rates of thermal spray processes compared to sintering methods.
• Reduced risk of breakage during manufacturing and assembly of large diffusion bodies.
• Improved oxidation resistance and longevity through the use of noble metal additives (such as platinum, gold, or iridium).
• Ability to create graded porosity structures, optimizing performance for various electrochemical environments.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The present invention relates to a gas diffusion body (5) comprising at least one base layer (7a, 7b, 7c) having through-openings (9), which is made of electrically conductive expanded metal, of electrically conductive fabric or mesh or of an electrically conductive metal plate provided with through-openings, wherein the gas diffusion body (5) has at least one additional layer (8a, 8b, 8c), which is applied as a powdery material using a thermal spraying process, wherein the powdery material consists at least largely of particles of electrically conductive material, in particular to a proportion of at least 70 wt.-%, preferably to a proportion of at least 90 wt.-%.