Porous Transport Layer Based on Plurality of Sintered Porous Layers

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This invention introduces a multilayer porous transport layer (PTL) made from various sintered, non-spherical conductive particles with a gradation of particle sizes, intended for use in electrochemical cells such as fuel cells and water electrolyzers. The PTL has layers where the particles become progressively smaller toward the catalyst layer, improving contact, mechanical stability, and fluid transport. The structure may include protective coatings (e.g., gold, platinum) and integrated flow channels to further enhance performance and reduce manufacturing costs.

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

• Polymer electrolyte water electrolysis (PEWE) for hydrogen production
• Polymer electrolyte fuel cells (PEFC) for power generation (e.g., automotive, stationary applications)
• Industrial electrochemical reactors requiring efficient fluid/gas management and durability
• Electrochemical devices requiring cost-effective and robust bipolar plate and catalyst interfaces
• Applications in energy conversion and storage systems needing improved mass transport and stability

BenefitsContent extracted from patent full text and abstract with AI.

• Improved system efficiency due to optimized multilayer structure and enhanced fluid and gas transport
• Superior mechanical durability, reducing membrane and catalyst layer deformation and extending component life
• Lower manufacturing and component costs through integrated flow channels and simplified machining
• Enhanced surface and interfacial properties, reducing ohmic losses and improving catalyst utilization
• Corrosion resistance via protective coatings to prevent degradation (e.g., titanium oxide build-up)
• Enables the use of thinner membranes, potentially increasing system performance and reducing hydrogen crossover
• Supports greater design flexibility (e.g., by using additive manufacturing for custom flow channels)

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Patent Abstract

It is therefore the objective of the present invention to provide a porous transport layer that shows an increase in the system efficiency as well as superior durability eliminating membrane and catalyst layer deformation and cost reduction for bipolar plate machining.This objective is achieved according to the present invention by a porous transport layer (2) based on a plurality of sintered porous layers (4, 8, 10) having a permeability for gaseous and liquid substances in an electrochemical cell; said multilayer porous transport layer (2) being suited to be assembled between a bipolar plate and a catalyst layer of the electrochemical cell, comprising:a) at least a first porous layer (8, 10) and a second porous layer (4) comprising non-defined shaped particles of a conductive material, wherein the mean particle size decreases from layer to layer in a direction seen from the bipolar plate towards the catalyst layer; andb) the first porous layer (8, 10) and the second layer (4) are made from sintered non-defined shaped particles of the conductive material, wherein the first porous layer (8, 10) having a contact surface enabled to be oriented towards the catalyst layer has a smaller mean particle size than the second porous layer (4) having a contact surface enabled to be oriented towards the bipolar plate.The use of multilayer designed porous transport structures, comprised of a plurality of porous layers in optional combination with integrated flow field structures provides simultaneously economic and technical improvement by the optimization of a single component design.