Hybrid Structured Porous Transport Electrodes with Electrochemically Active Top-layer

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This invention describes a hybrid, multilayer porous transport electrode (PTE) designed for electrochemical cells such as fuel cells and water electrolyzers. The electrode consists of several sintered porous layers with tailored pore sizes and particle geometries, topped with an electrochemically active layer. This structure enhances efficiency, catalyst utilization, and durability while reducing both manufacturing complexity and costs by integrating multiple components into a single unit.

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• Polymer electrolyte water electrolyzers (PEWE) for hydrogen production
• Polymer electrolyte fuel cells (PEFC) for clean power generation
• Redox flow batteries or similar electrochemical energy storage systems
• Electrochemical sensors and reactors requiring efficient gas/liquid/electron transport
• Industrial scale-up of hydrogen or oxygen production systems with limited catalyst supply

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly improved efficiency and catalyst utilization by optimal layer design and direct contact between catalyst and support
• Enhanced durability and longer electrode and membrane lifespan due to reduced mechanical stress and improved interface properties
• Supports use of low catalyst loadings, addressing issues with expensive or scarce catalyst materials like iridium
• Reduced mass, electrical, and ionic transport losses due to thinner catalyst layers and optimized porosity
• Lower capital and operational expenses by unifying multiple functions into a single, compact component
• Better thermal and electrical conductivity, and controlled gas/liquid flow through gradient pore structures
• Compatibility with established and scalable manufacturing processes like sintering and thin-film deposition

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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; and b) 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; and c) 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.