Gm Global Technolgoy Operations, Inc.

Other

Asahi Glass Company, Limited

Johnson Matthey Fuel Cells Limited

Johnson Matthey Public Limited Company

General Motors LLC

Bhaskar Sompalli

Hubert Gasteiger

Susan Yan

Brian A Litteer

Robert L Fuss

Hiroshi Shimoda

Mark F Mathias

Chunxin Ji

Jeffrey Allan Rock

Steven G Goebel

Gerald W Fly

Anthony B LaConti

Yeh-Hung Lai

Matthew J Beutel

Toshihiro Tanuma

Michael R Schoeneweiss

Seigo Kotera

Brian K Brady

Michael Scozzafava

Shinji Terazono

Shinji Kinoshita

Hirokazu Wakabayashi

Wenbin Gu

Joerg Roth

John P Healy

Adam John Hodgkinson

Matthew M Fay

Kohta Yamada

Catherine Helen De Rouffignac

Peter Anthony Trew

John C Doyle

Atsuo Okawara

David Wood

Robert Milgate

Susan G Yan

A membrane electrode assembly comprises an ion-conducting membrane; a first electrocatalyst layer having a surface facing the membrane; a first electronically-conducting porous gas diffusion substrate facing the other surface of the first electrocatalyst layer; and a first film member interposed between the membrane and the first electrocatalyst layer. The first electrocatalyst layer has an edge region and a central region, and the first film member contacts the edge region and not the central region. A first adhesive layer is present on the surface of the first film member facing the first electrocatalyst layer, and the first adhesive layer adheres the first film member to the first electrocatalyst layer, impregnates through the first electrocatalyst layer, and impregnates into the first gas diffusion substrate.

Membrane electrode assembly having an adhesive layer impregnating through an electrocatalyst layer and into a first gas diffusion substrate

A process comprising: providing a substrate with a catalyst layer thereon; depositing a first ionomer overcoat layer over the catalyst layer, the first ionomer overcoat layer comprising an ionomer and a first solvent; drying the first ionomer overcoat layer to provide a first electrode ionomer overcoat layer; depositing a second ionomer overcoat layer over the first electrode ionomer overcoat layer, and wherein the second ionomer overcoat layer comprises an ionomer and a second solvent.

Method of making fuel cell components including a catalyst layer and a plurality of ionomer overcoat layers

A fuel cell including a membrane electrode assembly composed of a ionically conductive member sandwiched between a pair of electrodes. At least one of the electrodes including a catalyst loading characterized by catalytic activity that varies in proportion to the catalyst loading. Moreover, the fuel cell includes a flow path for supplying gaseous reactants to the electrodes and the catalyst loading is varied according to the flow path geometry.

Variable catalyst loading based on flow field geometry

A fuel cell including an anode-side catalyst coated diffusion medium and a cathode-side catalyst coated diffusion medium that sandwich an ionically conductive membrane. A sealing material is disposed between the ionically conductive membrane and the anode-side and cathode-side catalyst coated diffusion medium, wherein the sealing material is formed of a material that has a permeability that is less than a permeability of the ionically conductive member. The sealing material may also be formed of a material that is softer than the ionically conductive membrane such that the sealing material may deform and enable an membrane electrode assembly of the fuel cell to be subjected to uniform pressures throughout the assembly.

Edge-protected catalyst-coated diffusion media and membrane electrode assemblies

A fuel cell including an anode-side catalyst coated membrane and a cathode-side catalyst coated membrane. At least a portion of a reduced-permeability layer is disposed between the ionically conductive membrane and the anode-side and cathode-side gas diffusion media, wherein the reduced-permeability layer is formed of a material that has a permeability that is less than a permeability of the ionically conductive member. The reduced-permeability layer may also be formed of a material that is softer than the ionically conductive membrane.

Edge-protected catalyst-coated membrane electrode assemblies

A membrane electrode assembly including an ionically conductive member, an electrode, and an electrically conductive member including an active layer, wherein the electrode is a smooth, continuous layer that completely covers and supports the ionically conductive member. The electrode and active layer further include a first and second catalyst content, respectively; and 50% of the total catalyst content is present in the electrode and 50% of the total catalyst content is present in the active layer.

Split architectures for MEA durability

A process comprising: depositing a liquid bonding layer comprising an ionomer and a solvent over a carrier film; placing a decal substrate over the liquid bonding layer and drying the liquid bonding layer to provide a solid bonding layer comprising the ionomer, and the solid bonding layer bonding the decal substrate and carrier film together.

Method of laminating a decal to a carrier film

A membrane electrode assembly comprising an ionically conductive member and an electrode, wherein the electrode is a smooth, continuous layer that completely covers and supports the ionically conductive member. The electrode further comprises a central region and a peripheral region, wherein a gradient of electrochemically active material exists between the central region and the peripheral region such that a content of the electrochemically active material is greater in the central region than the peripheral region.

Catalyst layer edge protection for enhanced MEA durability in PEM fuel cells

A method of manufacturing a fuel cell membrane electrode assembly comprising forming and compressing a stack having a plurality of layers in a desired orientation. The layers comprise a membrane, a cathode, an anode, and at least one edge protection layer. The method includes providing at least one mechanical reinforcing layer adjacent the anode or cathode layer, and allowing the electrodes to relax under high heat to remove stress prior to lamination.

Catalyst coated diffusion media

A diffusion media for use in a PEM fuel cell which includes a relieved edge region relative to the interior region of the diffusion media. The outer perimeter or portion of the diffusion media that will interface with a sealing gasket is pre-compressed. The pre-compressed diffusion media lowers the compression stress on the MEA at the gasket interfaces, enabling a more uniform compression on the entirety of the MEA surfaces during the build, compression, and later operation of a fuel cell stack.

Edge stress relief in diffusion media

A porous diffusion media according to the present invention is positioned against a catalyst layer of the membrane electrode assembly, the porous matrix comprises carbon paper, and the water transfer particles comprise carbon fibers or powders. Relatively high and relatively low water transfer particle density regions alternate across the porous diffusion media. A first major face of the media may be collectively more hydrophilic than the second major face and the second major face may be collectively more hydrophobic than the first major face. The diffusion media is positioned against the catalyst layer along the first major face of the diffusion media and against a flow field of the fuel cell along the second major face of the diffusion media. The porous diffusion media comprises hydrophobic material disposed along the second major face of the diffusion media.

Diffusion media, fuel cells, and fuel cell powered systems

A technique for fabricating an MEA for a fuel cell that is prepared as a catalyst-coated diffusion media (CCDM). The MEA includes a diffusion media layer having a microporous layer. A catalyst layer is deposited on the microporous layer so that it covers its entire surface. An ionomer layer is sprayed on the catalyst layer. A perfluorinated membrane is sandwiched between one CCDM at the anode side of the MEA and another CCDM at the cathode side of the MEA where the ionomer spray layers face the membrane.

Durable membrane electrode assembly catalyst coated diffusion media with no lamination to membrane

The present invention relates to an electrochemical cell having a terminal collector plate element that conducts electrical current from the stack. The terminal plate has an electrically conductive region and an electrically non-conductive region of the surface. The non-conductive region is coated with a corrosion resistant coating that comprises either a passivation layer, a corrosion-resistant polymeric layer, or both. Optionally, the conductive region of the terminal plate may be protected from oxidation, by coating with an oxidation-resistant metal layer. The oxidation-resistant layer may be further coated with a conductive oxidation-resistant polymeric layer. Other preferred aspects of the present invention include methods of treating the terminal plate to resist corrosion and oxidation while still maintaining electrical conductivity.

Corrosion resistant fuel cell terminal plates

Growing community of inventors

Rochester, NY, United States of America

Bhaskar Sompalli