公开(公告)号：US20250062366A1

公开(公告)日：2025-02-20

申请号：US18684042

申请日：2022-09-02

Applicant: BLue-O Technology Inc.

Inventor： Hai Xiong Ruan ,  Emad Azmy Sultan Girgis

IPC: H01M4/88 ,  C25B11/054 ,  C25B11/065 ,  C25B11/081 ,  C25D15/00 ,  H01M4/86 ,  H01M4/92

Abstract: A novel catalyst layer (CL) composition and structure that provides exceptional durability with sustained catalytic performance for intended heavy duty vehicle (HDV) application. This inventive composition and structure of the CL includes an internal composition composed of binder-coated nanoparticles, binder-free catalyst nanoparticles and orderly electric, ionic, gas and liquid pathways; a multi-layered structure of different packing densities among multiple sublayers; and external patterning of an outer surface of the CL. Extended durability and catalytic performance of the CL is achieved, and through use of the inventive CL, a novel solid-state electroplating process is demonstrated to achieve a novel thin-film coated catalyst product. The binder-coated nanoparticles serve as an interconnection base or site to whose binder-coated surface the uncoated nanoparticles are attached in glue-like fashion, achieving an orderly structure in which binder-free catalyst nanoparticles are consistently interspersed between binder-coated nanoparticles and agglomerates thereof.