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

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This patent describes a new method and device for creating a membrane-electrode assembly (MEA) used in proton exchange membrane (PEM) fuel cells and electrolyzers. The invention introduces a self-supporting nanoporous catalyst layer made of noble metal grains that increase the surface area and enhance catalytic activity between the electrode and membrane.

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• PEM fuel cells for vehicles and stationary power generation
• Electrolyzers for hydrogen production through water splitting
• Portable power devices using fuel cell technology
• Backup power systems using fuel cells
• Advanced energy systems requiring efficient catalysis

BenefitsContent extracted from patent full text and abstract with AI.

• Increased catalytic surface area enhances the efficiency of chemical reactions within the cell.
• Self-supporting design reduces the need for additional supporting materials, potentially lowering weight and complexity.
• Improved overall performance of fuel cells and electrolyzers through better catalyst utilization.
• Potential reduction in noble metal usage due to enhanced catalytic effectiveness.
• Greater durability and stability of the catalyst layer, leading to longer device lifetimes.

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Patent Abstract

The present invention relates to a membrane-electrode-assembly for a proton exchange membrane (PEM) fuel cell or an electrolyzer comprising the following components: a first gas-permeable electrode layer, a first self-supporting nanoporous catalyst layer comprising a noble metal, and a membrane, wherein the first self-supporting nanoporous catalyst layer extends between the first gas-permeable electrode layer and the membrane, characterized in that the first self-supporting nanoporous catalyst layer is formed by a plurality of grains of a first catalyst compound, wherein gaps are formed in between the grains such as to form an increased surface area of the first self-supporting nanoporous catalyst layer for enhancing catalytic reactions, wherein the first self-supporting nanoporous catalyst layer is self-supported by the noble metal.