Method for Forming a Catalytically-Active Membrane or a Membrane-electrode-assembly

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This patent describes a novel method for manufacturing a catalytically-active membrane-electrode assembly (MEA), crucial for devices like proton exchange membrane (PEM) fuel cells and electrolyzers. The method involves depositing a heterogeneous layer of base and noble metals onto a substrate, selectively removing (leaching) the base metal to produce a nanoporous, self-supporting noble metal catalyst layer, adding functional components for improved proton conductivity and water management, and attaching the catalyst layer(s) to a membrane to form a high-performance MEA.

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• Proton exchange membrane (PEM) fuel cells for clean energy generation in vehicles, portable devices, or stationary power plants.
• PEM electrolyzers for efficient hydrogen production via water splitting in green hydrogen technologies.
• Advanced electrochemical sensors utilizing highly active and durable catalyst layers.
• Energy storage systems where efficient and robust electrode assemblies are required.
• Electrolysis or fuel cell stacks for industrial-scale applications, such as backup power or grid stabilization.

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• Provides a nanoporous, self-supporting catalyst layer with high surface area, thereby increasing catalytic activity and efficiency.
• Reduces or eliminates the need for additional support materials, minimizing contaminant risks and enhancing durability in harsh, corrosive environments.
• Allows precise control over catalyst composition and structure, potentially lowering the use of expensive noble metals.
• Improves the contact between catalyst layer and membrane, boosting overall performance and longevity of fuel cells and electrolyzers.
• Enables scalable and flexible manufacturing methods (e.g., PVD, decal transfer), supporting both small and large-scale production.
• Enhances water management and proton conductivity through incorporation of ionomers, hydrophobic particles, or ionic liquids, optimizing efficiency.

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Patent Abstract

The present invention relates to a method for manufacturing a catalytically-active membrane-electrode-assembly (20) with one or more, particularly two electrodes, the method comprising at least the steps of:i) depositing a heterogenous layer (3) on a substrate (5), the heterogeneous layer (3) comprising a base metal (1) and a noble metal (2) heterogeneously distributed in the heterogenous layer (3),ii) leaching of the base metal (1) out of the heterogeneous layer (3), such that a first self-supporting nanoporous catalyst layer (4) comprising the noble metal (2) is formed on the substrate (5),iii) adding of at least one kind of proton-conductive ionomers (40) and/or at least one kind of hydrophobic particles (41) and/or an ionic liquid (42) to the first self-supporting nanoporous catalyst layer (4), andv) forming a catalytically-active membrane-electrode-assembly (20) by attaching the self-supporting nanoporous catalyst layer (4) to a first side of a membrane (10), such that a catalytically-active membrane-electrode-assembly (20) with one electrode is formed.