Abstract:
A method of forming a fuel cell catalyst layer. The method includes spinning a composition including a base polymer, a solvent, and a catalyst precursor into a non-woven fiber mat having the catalyst precursor embedded therein. The method further includes carbonizing the non-woven fiber mat to form a carbon fiber substrate. The method also includes reacting the catalyst precursor to form a plurality of individual catalyst particles embedded in the carbon fiber substrate.
Abstract:
In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 μm, and a plurality of bores with a diameter of 0.5 to 100 μm. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.
Abstract:
A fuel cell system includes a plurality of fuel cells. Each of the fuel cells may include a current bypass device that is configured to flow a current responsive to an anode potential exceeding a cathode potential to prevent carbon corrosion within the fuel cell.
Abstract:
A fuel cell oxidation reduction reaction catalyst comprising a carbon substrate, an amorphous metal oxide intermediate layer on the substrate, and an intertwined matrix of platinum and elemental niobium arranged to form a surface metal layer covering the intermediate layer such that upon oxidation, the niobium binds with oxygen resulting in strengthened bonds between the platinum and the intermediate layer.
Abstract:
A fuel cell oxidation reduction reaction catalyst comprising a carbon substrate, an amorphous metal oxide intermediate layer on the substrate, and an intertwined matrix of platinum and elemental niobium arranged to form a surface metal layer covering the intermediate layer such that upon oxidation, the niobium binds with oxygen resulting in strengthened bonds between the platinum and the intermediate layer.
Abstract:
A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode. The microporous includes a first carbon-based material layer comprising a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 μm and a plurality of bores with a diameter of 1 to 20 μm. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.
Abstract:
In at least one embodiment, an oxygen reduction reaction catalyst (ORR) and a method for making the catalyst are provided. The method may include depositing a metal oxide on a graphitized carbon or graphene substrate. A platinum catalyst may then be deposited over the metal oxide to provide an ORR catalyst for use in, for example, a PEMFC. The metal oxide may be niobium oxide and may have an amorphous structure. The platinum catalyst may form a thin, electrically interconnected network structure overlaying the metal oxide. The ORR catalyst may be prepared by alternating the deposition of the metal oxide and the platinum catalyst, for example, using physical vapor deposition. The ORR catalyst may have a specific activity of at least 1,000 μA/cm2 Pt and may approach or achieve bulk Pt activity.
Abstract:
A fuel cell assembly includes an anode with a catalyst layer and a gas inlet end, and a cathode with a catalyst layer and a gas inlet end. The assembly comprises a catalyst layer including a first and second set of catalyst segment pairs spaced apart respectively with first and second distances, a first ratio of an average segment width of the first set of catalyst segment pairs relative to the first distance being different from a second ratio of an average segment width of the second set of catalyst segment pairs relative to the second distance.
Abstract:
In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 μm and a plurality of bores having a diameter of 1 to 100 μm. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.
Abstract:
A fuel cell assembly includes an anode with a catalyst layer and a gas inlet end, and a cathode with a catalyst layer and a gas inlet end. The assembly comprises a catalyst layer including a first and second set of catalyst segment pairs spaced apart respectively with first and second distances, a first ratio of an average segment width of the first set of catalyst segment pairs relative to the first distance being different from a second ratio of an average segment width of the second set of catalyst segment pairs relative to the second distance.