3m Innovative Properties Company

Alison K Schmoeckel

Radoslav Atanasoski

George D Vernstrom

Thomas Edward Wood

Dennis P O'Brien

David G O'Neill

Mark Kevitt Debe

Jeffrey R Dahn

Susan M Hendricks

Ruizhi Yang

E Bradley Easton

Clayton V Hamilton, Jr

This invention relates to non-precious metal fuel cell cathode catalysts, fuel cells that contain these catalysts, and methods of making the same. The fuel cell cathode catalysts are highly nitrogenated carbon materials that can contain a transition metal. The highly nitrogenated carbon materials can be supported on a nanoparticle substrate.

High performance, high durability non-precious metal fuel cell catalysts

An oxygen-reducing catalyst layer, and a method of making the oxygen-reducing catalyst layer, where the oxygen-reducing catalyst layer includes a catalytic material film disposed on a substrate with the use of physical vapor deposition and thermal treatment. The catalytic material film includes a transition metal that is substantially free of platinum. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

Oxygen-reducing catalyst layer

A method is provided for making a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles, where the method comprises step a) of vacuum deposition of material from at least a first carbon target in the presence of nitrogen and step b) of vacuum deposition of material from a second target comprising at least one transition metal, the second target comprising no precious metals. In one embodiment, step a) is carried out prior to step b). In another embodiment, steps a) and b) are carried out simultaneously. Typically the deposition steps are carried out in the absence of oxygen. Typically, the transition metal is iron or cobalt, and most typically iron. The present disclosure also provides a supported catalyst comprising nanostructured elements which comprise microstructured support whiskers bearing nanoscopic catalyst particles made according to the present method. The present disclosure also provides a fuel cell membrane electrode assembly comprising the present supported catalyst.

Fuel cell catalyst

Methods are provided for making oxygen-reducing catalyst layers, which include simultaneous or sequential stops of physical vapor depositing an oxygen-reducing catalytic material onto a substrate, the catalytic material comprising a transition metal that is substantially free of platinum; and thermally treating the catalytic material. At least one of the physical vapor deposition and the thermal treatment is performed in a processing environment comprising a nitrogen-containing gas.

Method for making oxygen-reducing catalyst layers

A fuel cell cathode catalyst is provided comprising nanostructured elements comprising microstructured support whiskers bearing nanoscopic catalyst particles; wherein the catalyst comprises platinum and manganese and at least one other metal selected from the group consisting of Group VIb metals, Group VIIb metals and Group VIIIb metals other than platinum and manganese; wherein the volume ratio of platinum to the sum of all other metals in the catalyst is between about 1 and about 4 and wherein the Mn content is equal to or greater than about 5 micrograms/cm2 areal density. Typically, the volume ratio of manganese to the at least one other metal is between 10:90 and 90:10. Typically, the at least one other metal is Ni or Co. In addition, a fuel cell MBA comprising the present cathode catalyst is provided. In addition, methods of making the present cathode catalyst are provided.

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Stillwater, MN, United States of America

Alison K Schmoeckel