Gm Global Technolgoy Operations, Inc.

University of Colorado

Anusorn Kongkanand

Frederick T Wagner

Eric L Thompson

Steven McClellan George

Michael Kevin Carpenter

Joel W Clancey

Ratandeep S Kukreja

Yun Cai

Andrew Cavanaugh

Layton Baker

Mohammed Atwan

A method for forming a caged electrocatalyst particles for fuel cell applications include a step of forming modified particles having a porous SiOshell on a surface of platinum-containing particles. The modified particles are subjected to acid treatment or electrochemical oxidation to remove a portion of the platinum-containing particle thereby creating caged electrocatalyst particles having a gap between the platinum-containing particles and their SiOshell.

Caged nanoparticle electrocatalyst with high stability and gas transport property

A method of making a fuel cell including the following steps: comprising: (a) mixing carbon nanotubes (CNT) with an initial dispersion, wherein the initial dispersion includes an ionomer; (b) heating and stirring the initial dispersion to form a CNT-ionomer composite suspension; (c) after forming the CNT-ionomer composite suspension, mixing the CNT-ionomer composite suspension with an electrode catalyst solution to form an electrode ink, wherein the electrode catalyst solution includes a carbon black powder and a catalyst supported by the carbon black powder; and (d) coating a proton exchange membrane with the electrode ink to form the fuel cell electrode.

Fuel cell with segregated electrolyte distribution and method for making the same

A method for forming a corrosion-resistant catalyst for fuel cell catalyst layers is provided. The method includes a step of depositing a conformal Pt or platinum alloy thin layer on NbOsubstrate particles to form Pt-coated NbO. The Pt-coated NbOparticles are then incorporated into a fuel cell catalyst layer.

Corrosion-resistant catalyst

A coated substrate for forming fuel cell catalyst layers includes a plurality of substrate particles, an adhesion layer disposed over the substrate particles, and a precious metal layer disposed over the adhesion layer. The substrate particles may be carbon powders, carbon nanorods, carbon nanotubes and combinations thereof; with a preferred aspect ratio from 10:1 to 25:1. The adhesion layer includes a tungsten metal layer and may be formed into a heterogeneous layer comprising a lattice-interrupting layer interposed between two tungsten metal layers. The lattice-interrupting layer reduces mechanical stress to the adhesion layer with extended thickness that may develop when it experiences changing environments, and can be any layer other than the metal layer, for example, AlO, Al, or WO, where x is 1.5 to 3.0. Characteristically, the coated substrate is used in fuel cell applications such as providing the catalyst particles used in the cathode and/or anode catalyst layers.

Conformal thin film of precious metal on a support

A method for forming a carbon supported catalyst includes a step of providing a first carbon supported catalyst having a platinum-group metal supported on a first carbon support. Characteristically, the first carbon support has a first average micropore diameter and a first average carbon surface area. The first carbon supported catalyst is contacted with an oxygen-containing gas at a temperature less than about 450&#xb0; C. for a predetermined period of time to form a second carbon supported catalyst, wherein the first carbon support or the second carbon supported catalyst is acid leached.

Facile control of pore structure in carbon-supported PGM-based catalysts

A method for forming a fuel cell catalyst includes a step of forming an ionomer-containing layer including carbon particles and an ionomer. Tungsten-nickel alloy particles are formed on the carbon particles. At least a portion of the nickel in the tungsten-nickel alloy particles is replaced with palladium to form palladium-coated particles. The palladium-coated particles include a palladium shell covering the tungsten-nickel alloy particles. The palladium-coated particles are coated with platinum to form an electrode layer including core shell catalysts distributed therein.

Roll-to-roll fabrication of high performance fuel cell electrode with core-shell catalyst using seeded electrodes

A method for making tungsten-alloy nanoparticles that are useful for fuel cell applications includes a step of combining a solvent system and a surfactant to form a first mixture. A tungsten precursor is introduced into the first mixture to form a tungsten precursor suspension. The tungsten precursor suspension is heated to form tungsten nanoparticles. The tungsten nanoparticles are combined with carbon particles to form carbon-nanoparticle composite particles. The carbon-nanoparticle composite particles are combined with a metal salt to form carbon-nanoparticle composite particles with adhered metal salt, the metal salt including a metal other than tungsten. The third solvent system is then removed. A two-stage heat treatment is applied to the carbon-nanoparticle composite particles with adhered metal salt to form carbon supported tungsten-alloy nanoparticles. A method for making carbon supported tungsten alloys by reducing a tungsten salt and a metal salt is also provided.

Synthesis of alloy nanoparticles as a stable core for core-shell electrocatalysts

One embodiment includes a method of forming a hydrophilic particle containing electrode including providing a catalyst; providing hydrophilic particles suspended in a liquid to form a liquid suspension; contacting said catalyst with said liquid suspension; and, drying said liquid suspension contacting said catalyst to leave said hydrophilic particles attached to said catalyst.

Method of enhancing electrodes

A method for preparing hollow platinum or platinum-alloy catalysts includes a step of forming a plurality of low-melting-point metal nanoparticles. A platinum or platinum-alloy coating is then deposited onto the low-melting-point metal nanoparticles to form platinum or platinum-alloy coated particles. The low-melting-point metal nanoparticles are then removed to form a plurality of hollow platinum or platinum-alloy particles.

Preparation of hollow Pt and Pt-alloy catalysts

A fuel cell including at least one of a hydrophilic interlayer and a flow field treated to impart hydrophilic properties is disclosed, wherein the hydrophilic interlayer and the treated flow field militate against water accumulation in ultrathin electrodes of the fuel cell, particularly for cool-start operating conditions (i.e. about 0&#xb0; C. to about 60&#xb0; C.).

Material design to enable high mid-temperature performance of a fuel cell with ultrathin electrodes

One embodiment includes at least one of the anode and cathode of a fuel cell comprises a first layer and a second layer in intimate contact with each other. Both the first layer and the second layer comprise a catalyst capable of catalyzing an electrochemical reaction of a reactant gas. The second layer has a higher porosity than the first layer. A membrane electrode assembly (MEA) based on the layered electrode configuration and a process of making a fuel cell are also described.

Fuel cell with layered electrode

A method to achieve a conformal ultrathin film of platinum or one of its alloys on a substrate that can be economically used as a heterogeneous catalyst, such as automotive polymer electrolyte membrane (PEM) fuel cell catalyst. The method includes using a hydrogen plasma in platinum atomic layer deposition along with tungsten as a substrate or anchoring adhesive layer to assist platinum nucleation and deposition.

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Rochester Hills, MI, United States of America

Anusorn Kongkanand