Hybrid Structured Porous Transport Electrodes with Electrochemically Active Top-layer

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This invention is a new type of compact, multilayered porous transport electrode for use in electrochemical cells such as water electrolyzers and fuel cells. The electrode is structured with several thin, sintered porous layers made of conductive fibers and particles with a gradient in pore/particle size, and is topped with an electrochemically active layer. This design significantly enhances efficiency, durability, and catalyst utilization, while integrating multiple cell components into a single, manufacturable structure.

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

• Water electrolyzers for hydrogen production (PEWE, PEM electrolyzers)
• Fuel cells, especially proton exchange membrane (PEM) fuel cells
• Electrochemical synthesis cells
• Industrial applications requiring efficient gas/liquid electrochemical reactions
• Renewable energy storage and conversion systems
• Electrochemical devices operating under harsh or acidic conditions

BenefitsContent extracted from patent full text and abstract with AI.

• Higher cell efficiency due to improved transport of gases and liquids through optimized pore structure
• Superior mechanical durability preventing catalyst and membrane degradation
• Significantly increased catalyst utilization, especially at lower catalyst loadings, reducing use of expensive materials like iridium
• Single-component integration decreases manufacturing complexity and costs (both operational and capital expenditures)
• Extended device lifetime due to reduced mechanical and electrochemical stress on components
• Potential for thinner catalyst layers, lowering electrical, ionic, and mass transport losses
• Easier scalability and improved reliability for large-scale hydrogen or fuel cell systems

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Inventors & Applicants

Patent Abstract

It is the objective of the present invention to provide a compact porous transport electrode that shows an increase in cell efficiency as well as superior durability eliminating the problem of low catalyst utilization for low and high catalyst loadings and catalyst layer degradation. At the same time, the unifying of multiple components in a single component design results in reduced capital expenditures.This objective is achieved according to the present invention by a hybrid, porous transport electrode based on a plurality of thin sintered porous layers and at least a electrochemically active top layer having a permeability for gaseous and liquid substances in an electrochemical cell; said multilayer porous transport electrodes being suited to be assembled between a bipolar plate and a membrane of the electrochemical cell, comprising:a) at least a first support porous layer and a second intermediate porous layer comprising fibres and non-defined shaped particles of a conductive material, wherein the mean particle size decreases from layer to layer in the direction seen from the bipolar plate towards the membrane; andb) the first porous layer being made from sintered fibres of the conductive material and the second layer being made from non-defined shaped particles of a conductive material, wherein the first porous layer having a contact surface enabled to be oriented towards the bipolar plate having a bigger pore size than the second porous layer having a contact surface enabled to be oriented towards the membrane; andc) the electrochemically active top layer comprising an electrochemically active material or mixtures thereof being deposited on the second porous layer, wherein the electrochemically active top layer having a contact surface enabled to be oriented towards the membrane and having a smaller pore size than the second porous layer and first porous layer.The employment of hybrid designed porous electrode structures, comprised of a plurality of porous layers and at least one electrochemically active top layer in optional combination with thermal and electrical conductivity coating provides simultaneously economic and technical improvement by performance optimization und the unification of multicomponent in a single component design.