Method for Producing Catalyst-Coated Membranes

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This invention discloses a method to produce catalyst-coated polymer membranes, which are central components in electrolyzers and fuel cells. The process involves depositing a mesoporous nanostructured catalyst layer on a glass-ceramic substrate, then transferring this layer onto a polymer membrane by pressing them together at a specific temperature, creating a strong and highly active catalytic interface. The glass-ceramic substrate allows for the formation and transfer of a fragile, high-performance mesoporous catalyst layer that could not be produced directly on the membrane.

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

• Manufacture of advanced polymer electrolyte membranes for fuel cells, improving their catalytic efficiency.
• Production of high-performance membranes for water electrolyzers used in green hydrogen generation.
• Fabrication of catalyst-coated membranes for energy conversion and storage devices.
• Use in sectors striving for efficient hydrogen production or electrochemical energy conversion, such as automotive, stationary power, or portable energy devices.
• Potential adaptation for creating carrier membranes for drug delivery or filtration, leveraging controllable porous structures.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables the creation of nanostructured mesoporous catalyst layers with significantly enhanced catalytic activity compared to conventional coatings.
• Allows for rapid, reproducible, and scalable manufacturing, improving consistency and reducing costs.
• Avoids direct exposure of polymer membranes to harsh synthesis conditions, preserving membrane integrity.
• Increases the mass activity of valuable catalysts (e.g., Iridium or Ruthenium oxides), potentially reducing material usage and cost.
• Flexible method applicable to a wide range of membrane and catalyst materials, including for PEM fuel cells and electrolyzers.
• Improves the overall performance, durability, and service life of fuel cells and electrolyzers due to better catalyst-membrane interfaces.

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Patent Abstract

The invention relates to a method for producing a catalyst-coated polymer membrane for an electrolyzer and/or a fuel cell. The method preferably comprises, in a first step, the providing of a glass-ceramic substrate. Subsequently, a mesoporous catalyst layer is preferably synthesized onto the glass-ceramic substrate. In a subsequent step, a polymer membrane is preferably extruded at a first temperature T1 onto the glass-ceramic substrate coated with the catalyst layer. A sandwich structure is thereby obtained. In a final method step, the sandwich structure is separated, wherein the catalyst layer is released from the glass-ceramic substrate and adheres to the polymer membrane. The invention also relates to a polymer membrane that has been produced by the method of the type mentioned at the beginning, and also to an electrolyzer or a fuel cell with such a polymer membrane.