Membrane electrode assembly with tailored proton consuming electrode

Abstract

Aspects of the present disclosure include a membrane electrode assembly (MEA) having a tailored proton consuming electrode. An exemplary vehicle includes an electric motor, a battery, and a proton exchange membrane electrochemical cell. An electrochemical cell includes a proton-generating electrode, a proton-consuming electrode, and a membrane between the proton-generating electrode and the proton-consuming electrode (the proton-generating electrode, the proton-consuming electrode, and the membrane collectively define a membrane-electrode assembly), and a gas diffusion layer in direct contact with the proton-consuming electrode. The proton consuming electrode is trimmed relative to a first edge of the membrane and relative to a second edge of the membrane. The first edge is orthogonal to the second edge. The proton consuming electrode is tailored at a depth of focus that bypasses the membrane using laser ablation.

Description

Technical Field

[0001] This disclosure relates to hydrogen fuel cells and water electrolysis, and more particularly to membrane electrode assemblies (MEAs) having trimmed proton-consuming electrodes using a catalyst-coated diffusion medium-membrane attachment (CCDMm) process. Background Technology

[0002] Hydrogen fuel cells and related technologies have emerged as promising clean energy solutions, offering high efficiency and zero emissions for a wide range of applications, from transportation (e.g., personal and commercial vehicles, ships, aircraft, etc.) to stationary power generation. One type of hydrogen electrochemical cell is the proton exchange membrane (PEM) fuel cell (similarly, a PEM water electrolyzer). In a PEM fuel cell, hydrogen enters through the anode, where it is split into protons and electrons. The protons pass through the electrolyte membrane, while the electrons flow through an external circuit, thus generating electricity. At the cathode, the protons, electrons, and oxygen combine to produce water. Hydrogen fuel cells are typically implemented in fuel cell stacks, which are components of multiple individual hydrogen fuel cells connected in series to increase the total voltage and power output.

[0003] Hydrogen fuel cells require a supply of hydrogen fuel that can be provided via one or more electrolyzers. An electrolyzer is a device that uses electrical energy to drive a non-spontaneous chemical reaction that separates water (H₂O) into hydrogen (H₂) and oxygen (O₂) gases. An electrolyzer typically includes an anode, a cathode, and an electrolyte. When an electric current is applied between the anode and cathode, water molecules split at the anode to produce oxygen and protons (H₂O). + At the cathode, protons combine with electrons to produce hydrogen gas. Summary of the Invention

[0004] In one exemplary embodiment, a proton exchange membrane (PEM) electrochemical cell includes a proton generating electrode, a proton consuming electrode, a membrane located between the proton generating electrode and the proton consuming electrode (the proton generating electrode, the proton consuming electrode, and the membrane collectively define a membrane electrode assembly (MEA)), and a gas diffusion layer located in direct contact with the proton consuming electrode. The proton consuming electrode is trimmed relative to a first edge of the proton generating electrode and a second edge of the proton generating electrode. The first edge and the second edge are orthogonal. The proton consuming electrode is trimmed at a focal depth bypassing the membrane using laser ablation.

[0005] In addition to one or more features described herein, in some embodiments, the proton-consuming cathode electrode is applied directly to the gas diffusion layer.

[0006] In some embodiments, the film is applied to the proton-consuming electrode by direct coating or lamination.

[0007] In some embodiments, the PEM electrochemical cell is an electrolyzer.

[0008] In some embodiments, the electrolyzer includes a porous transport layer in direct contact with the proton generating electrode.

[0009] In some embodiments, the electrolyzer includes a gas diffusion layer in direct contact with the proton-consuming electrode.

[0010] In some embodiments, the gas diffusion layer is connected via a flow channel to an exhaust manifold configured to remove hydrogen from the electrolyzer.

[0011] In some embodiments, the PEM electrochemical cell is a fuel cell.

[0012] In some embodiments, the fuel cell includes a second gas diffusion layer in direct contact with the proton generation electrode.

[0013] In some embodiments, a gas diffusion layer is connected to an inlet manifold and an outlet manifold via flow channels. The inlet manifold is configured to supply oxygen to the fuel cell, and the outlet manifold is configured to remove water and air from the fuel cell.

[0014] In another exemplary embodiment, the vehicle includes an electric motor, a battery, and a PEM electrochemical cell. The PEM electrochemical cell includes a proton-generating electrode, a proton-consuming electrode, a membrane (the proton-generating electrode, the proton-consuming electrode, and the membrane collectively defining a MEA) located between the proton-generating electrode and the proton-consuming electrode, and a gas diffusion layer located in direct contact with the proton-consuming electrode. The proton-consuming electrode is trimmed relative to a first edge of the proton-generating electrode and a second edge of the proton-generating electrode. The first edge and the second edge are orthogonal. The proton-consuming electrode is trimmed at a focal depth bypassing the membrane using laser ablation.

[0015] In some embodiments, the proton-consuming cathode electrode is applied directly to the gas diffusion layer.

[0016] In some embodiments, the film is applied to the proton-consuming electrode by direct coating or lamination.

[0017] In some embodiments, the PEM electrochemical cell is an electrolyzer.

[0018] In some embodiments, the electrolyzer includes a porous transport layer in direct contact with the proton generating electrode.

[0019] In some embodiments, the electrolyzer includes a gas diffusion layer in direct contact with the proton-consuming electrode.

[0020] In some embodiments, the gas diffusion layer is connected via a flow channel to an exhaust manifold configured to remove hydrogen from the electrolyzer.

[0021] In some embodiments, the PEM electrochemical cell is a fuel cell.

[0022] In some embodiments, the fuel cell includes a second gas diffusion layer in direct contact with the proton generation electrode.

[0023] In some embodiments, a gas diffusion layer is connected to an inlet manifold and an outlet manifold via flow channels. The inlet manifold is configured to supply oxygen to the fuel cell, and the outlet manifold is configured to remove water and air from the fuel cell.

[0024] In yet another exemplary embodiment, the method may include forming a PEM electrochemical cell. The method includes forming a proton-generating electrode, forming a proton-consuming electrode, forming a membrane (the proton-generating electrode, the proton-consuming electrode, and the membrane collectively defining the MEA) between the proton-generating electrode and the proton-consuming electrode, and forming a gas diffusion layer in direct contact with the proton-consuming electrode. The method further includes trimming the proton-consuming electrode relative to a first edge and a second edge relative to the proton-generating electrode. The first edge and the second edge are orthogonal. The proton-consuming electrode is trimmed at a focal depth bypassing the membrane using laser ablation.

[0025] In some embodiments, the proton-consuming cathode electrode is applied directly to the gas diffusion layer.

[0026] In some embodiments, the film is applied to the proton-consuming electrode by direct coating or lamination.

[0027] In some embodiments, the PEM electrochemical cell is an electrolyzer.

[0028] In some embodiments, the method includes forming a porous transport layer in direct contact with a proton-generating electrode.

[0029] In some embodiments, the gas diffusion layer is connected via a flow channel to an exhaust manifold configured to remove hydrogen from the electrolyzer.

[0030] In some embodiments, the PEM electrochemical cell is a fuel cell.

[0031] In some embodiments, the method includes forming a second gas diffusion layer in direct contact with the proton generating electrode.

[0032] The above-described features and advantages, as well as other features and advantages, of this disclosure will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0033] Other features, advantages, and details appear as examples only in the following detailed description, with reference to the accompanying drawings.

[0034] Figure 1It is a vehicle configured according to one or more embodiments;

[0035] Figure 2A An electrolyzer according to one or more embodiments is described;

[0036] Figure 2B A fuel cell according to one or more embodiments is described;

[0037] Figures 3A-3D The sequential stages of a laser ablation technique for forming a catalyst-coated diffusion medium (CCDMm) with a modified proton-consuming electrode attached to a film, according to one or more embodiments, are described.

[0038] Figure 4A Depicting a target according to one or more embodiments Figure 3D The laser ablation technology shown is an alternative to laser ablation technology;

[0039] Figure 4B Depicting according to one or more embodiments Figure 4A The plan view of CCDMm shown below;

[0040] Figure 5 It is a computer system according to one or more embodiments;

[0041] Figure 6 It is a flowchart according to one or more embodiments;

[0042] Figure 7A This is a plan view of a proton exchange membrane (PEM) electrochemical cell according to one or more embodiments; and

[0043] Figure 7B For the interception along line AA according to one or more embodiments Figure 7A A cross-sectional view of a PEM electrochemical cell. Detailed Implementation

[0044] The following description is exemplary in nature and is not intended to limit this disclosure, its application or use.

[0045] Understanding and optimizing proton exchange membrane (PEM) type electrochemical cells, such as hydrogen fuel cells and electrolyzers (also known as electrolyzers), has become crucial for the widespread adoption and commercialization of hydrogen fuel cell technology. One of the key components in PEM type electrochemical cells is the membrane electrode assembly (MEA). In PEM cells, the MEA serves as the core functional unit where the main electrochemical reactions occur, converting chemical energy into electrical energy (in fuel cells) or electrical energy into chemical energy (in electrolyzers). More specifically, in PEM fuel cells, the MEA facilitates the oxidation of hydrogen at the anode and the reduction of oxygen at the cathode, producing electricity and the byproduct water, while in PEM electrolyzers, the MEA facilitates the splitting of water into hydrogen and oxygen using electricity.

[0046] As research progresses in hydrogen fuel cell technology, optimizing MEA design will continue to be a key driver for improving overall performance and durability. Unfortunately, in PEM cells, the migration of cations (such as those dissolved from the catalyst or membrane degradation modifier) ​​to the edges of the membrane electrode assembly (MEA) presents a significant challenge. This migration occurs due to the steep potential drop in the region where the proton-consuming electrode layer extends beyond the proton-generating electrode layer. The resulting cation migration can lead to the degradation of catalysts (such as platinum, iridium, etc.) or the depletion of modifiers (such as Ce3+ or Mn2+) in the active regions near these areas, thereby reducing the efficiency and durability of PEM electrochemical cells.

[0047] Existing solutions to cation migration in PEM electrochemical cells typically involve careful alignment of the proton-generating electrode layer and the proton-consuming electrode layer. However, these methods face limitations, particularly in conventional MEA architectures such as catalyst-coated films. Achieving precise alignment becomes increasingly challenging when using large-scale multilayer processes that rely on film lamination or direct film coating on the electrodes, as these methods introduce additional layers and processing steps. This hinders the ability to precisely control the overlap between the proton-generating and proton-consuming electrodes, leading to potential inefficiencies and reduced cell performance.

[0048] This disclosure introduces a novel MEA (Metal-Oxide-Anatomical) module and manufacturing method that addresses the problem of cation migration in PEM (Polymer-Enhanced Electrochemical) cells. Specifically, it provides an MEA module with trimmed proton-consuming electrodes. Instead of relying on alignment control between the proton-generating electrode layer and the proton-consuming electrode layer, femtosecond laser ablation is used to precisely trim the proton-consuming electrode layer at the MEA edge. This process ensures that the proton-generating electrode extends beyond the proton-consuming electrode layer, thereby controlling the potential gradient at the MEA edge and preventing cation migration away from the active region (or cation accumulation in the inactive edge). The femtosecond laser ablation method described herein allows for accurate and targeted removal of the electrode layer without damaging the film, thereby enhancing the performance and lifetime of the PEM electrochemical cell. Advantageously, the MEA module and manufacturing method described herein are compatible with both film lamination and direct film coating processes.

[0049] According to an exemplary embodiment, the vehicle is in Figure 1 The vehicle 100 is generally indicated by 100. The vehicle 100 is shown in the form of an automobile having a body 102. The body 102 includes a passenger compartment 104, within which a steering wheel, front seats, and rear passenger seats (not shown separately) are arranged. Several components are arranged within the body 102, including, for example, a fuel cell 106 (also referred to as a “fuel cell stack”), a hydrogen fuel storage tank 108, an intake manifold 110, a battery 112, and an electric motor 114 configured to use electrical energy to provide output torque to output components 116 (each component is shown by projection near the front hood). The fuel cell 106 receives a flow of hydrogen or other fuel gas from the hydrogen fuel storage tank 108 and a flow of air including oxygen from the intake manifold 110. The fuel cell 106 may include an air compressor unit (not shown separately) for pressurizing the air to a desired pressure. The fuel cell 106 may directly supply electrical energy to the electric motor 114 and / or the fuel cell 106 may supply electrical energy to the battery 112 for storage and later use. The output component 116 can provide output torque for, for example, to provide prime mover power to the vehicle 100. In some embodiments, the vehicle 100 includes an electrolyzer 118 (electrolytic cell) configured to produce hydrogen and deliver it to a hydrogen fuel storage tank 108 and / or a fuel cell 106.

[0050] The fuel cell 106, hydrogen fuel storage tank 108, intake manifold 110, battery 112, electric motor 114, and electrolyzer 118 are shown for ease of illustration and discussion only. It should be understood that the configuration, location, size, arrangement, etc., of these components are not particularly limited, and all such configurations (including multi-motor configurations) are within the scope of this disclosure. Furthermore, although this disclosure is discussed primarily in the context of the configuration of fuel cell 106 and electrolyzer 118 for vehicle 100, the aspects described herein can be similarly incorporated into any system (vehicle, building, or otherwise) having a hydrogen fuel cell-based electric and / or energy storage system, and all such configurations and applications are within the scope of this disclosure. In particular, the electrolyzer 118 does not need to be integrated into vehicle 100 at all, and in some embodiments, it is alternatively configured as a completely separate unit for independent hydrogen production (possibly for servicing vehicle 100 and other downstream applications).

[0051] Figure 2A An electrolyzer 118 according to one or more embodiments is depicted. For example... Figure 2A As shown, the electrolyzer 118 includes a porous transport layer (PTL) 202 and a proton generating electrode 204 (also known as an anode or H). + The generating electrode, membrane 206, proton consumption electrode 208 (also called cathode or H+ consumption electrode), and gas diffusion layer (GDL) 210 (sometimes called diffusion medium or DM) are configured and arranged as shown in the figure. In the electrolyzer type configuration, protons (H+) + The protons are generated in the proton-generating electrode 204 and pass through the membrane 206 to the proton-consuming electrode 208. In some embodiments, the proton-generating electrode 204 (anode) and the proton-consuming electrode 208 (cathode) are coupled to a power source (not separately indicated) that supplies current across the anode and cathode, such that water supplied to the electrolyzer 118 can be decomposed into hydrogen and oxygen. The combination of the proton-generating electrode 204, the membrane 206, and the proton-consuming electrode 208 together defines a membrane electrode assembly (MEA) 209.

[0052] In some embodiments, PTL 202 facilitates the uniform distribution of the reactant stream (typically water) on the proton-generating electrode 204 and onto the membrane 206. PTL 202 also aids in the efficient removal of byproducts, such as oxygen, from the electrolyzer 118. In some embodiments, PTL 202 is made of materials that provide a combination of high conductivity, chemical stability, mechanical strength, and porosity, such as, for example, sintered titanium, stainless steel, and nickel-based materials (such as nickel foam). The porous structure of PTL 202 allows water to be uniformly distributed across the active region of MEA 209 (refer to FIG. 7), enhancing the electrochemical reactions therein. Additionally, PTL 202 provides conductivity and mechanical support to the electrolyzer 118. In some embodiments, PTL 202 is connected to the inlet manifold 212 and the outlet manifold 214 via flow channels (not separately indicated). In some embodiments, the intake manifold 212 serves as an entry point (one or more) for the proton generating electrode layer 208 and the membrane 206, for the reactant stream (typically water), which is necessary for the electrochemical reactions occurring within the MEA 209. Conversely, the exhaust manifold 214 ensures the efficient removal of oxygen and excess water from the electrolyzer 118.

[0053] In some embodiments, the proton generating electrode 204 is positioned directly adjacent to the PTL 202 and between the PTL 202 and the membrane 206 (as shown in the figure). The proton generating electrode 204 is responsible for the oxidation of water molecules during electrolysis to produce oxygen and protons (H+). + Protons generated at proton-generating electrode 204 pass through membrane 206 to proton-consuming electrode 208, while electrons flow through external circuitry (not shown separately). Proton-generating electrode 204 is designed to facilitate efficient electrochemical reactions, ensuring optimal hydrogen production, and can be coupled to PTL 202 to ensure uniform water distribution and efficient oxygen removal.

[0054] In some embodiments, MEA 209 is located between PTL 202 and GDL 210. MEA 209 is the core functional unit of electrolyzer 118 and represents the active region where the main electrochemical reactions occur (e.g., active region 708, see Figure 7), converting electrical energy into chemical energy by splitting water into hydrogen and oxygen. MEA 209 may include several layers, including a proton exchange membrane (PEM, e.g., membrane 206), an anode catalyst layer (e.g., proton generating electrode 204), and a cathode catalyst layer (e.g., proton consuming electrode 208). PEM is a solid polymer electrolyte that conducts protons (H+, H ... +The proton generation electrode 204, acting as an insulator for electrons, ensures that protons generated at the anode can pass through and reach the cathode, while preventing the mixing of product gases. Catalyst layers are attached (laminated or directly coated) to both sides of the PEM and typically contain finely dispersed catalyst particles, such as platinum (Pt), supported on carbon particles. These catalyst layers facilitate the electrochemical reaction: at the anode, water molecules are oxidized to produce oxygen, protons, and electrons, while at the cathode, protons and electrons combine to form hydrogen. More specifically, the proton generation electrode 204 is sandwiched between the membrane 206 and the PTL 202 and contains finely dispersed catalyst particles, such as iridium (Ir) and / or titanium oxide particles. On the other hand, the proton consumption electrode 208 is sandwiched between the membrane 206 and the GDL 210 and contains finely dispersed catalyst particles, such as platinum (Pt), supported on carbon particles. The catalyst layer can be coated on membrane 206, coated on PTL 202, coated on GDL 210, and / or decal transferred to any one or all of membrane 206, PTL 202 and GDL 210.

[0055] In some embodiments, the proton-consuming electrode 208 is positioned directly adjacent to the membrane 206 and between the membrane 206 and the GDL 210 (as shown). The proton-consuming electrode 208 is responsible for reducing protons (H+) during the electrolysis process. + The proton-consuming electrode 208 facilitates the efficient combination of protons that have passed from the proton-generating electrode 204 through the membrane 206 with electrons that have traveled through an external circuit (e.g., a power source, not separately indicated). The proton-consuming electrode 208 is designed to promote efficient electrochemical reactions, ensure optimal hydrogen evolution, and can be coupled to the GDL 210 to ensure uniform removal of hydrogen from the electrolyzer 118.

[0056] like Figure 2A As further shown, the proton-consuming electrode 208 is trimmed relative to the proton-generating electrode 204 and the film 206. In some embodiments, the edge 211 of the proton-consuming electrode 208 is recessed using the femtosecond laser ablation technique described herein. In this way, the potential gradient at the film 206 near the proton-consuming electrode 208 is controlled, preventing cation migration to inactive regions and improving electrochemical cell performance and lifetime.

[0057] In some embodiments, GDL 210 is a porous material, such as carbon fiber paper or cloth, which facilitates the uniform discharge of hydrogen from MEA 209. In some embodiments, GDL 210 is connected to one or more outlet manifolds 216 via flow channels (not shown separately). In some embodiments, outlet manifolds 216 serve as outlet points (one or more) for the proton-consuming electrode layer 208 and membrane 206, for the byproduct (typically hydrogen).

[0058] Figure 2B A fuel cell 106 according to one or more embodiments is depicted. The fuel cell 106 is related to... Figure 2A The electrolyzer 118 discussed is similarly configured, except that, in a fuel cell configuration, the proton generating electrode 204 and the proton consuming electrode 208 are connected to a load (e.g., an electric motor, not shown separately), which is powered by the current generated by the fuel cell 106. Current is generated within the fuel cell 106 as water is produced by the reaction of hydrogen and oxygen. Specifically, hydrogen is oxidized at the proton generating electrode 204, electrons are conducted through an external circuit (not shown separately) typically connected to the load, and protons are conducted through the membrane 206. During this process, oxygen is reduced at the proton consuming electrode 208 to form water.

[0059] like Figure 2B As shown, the fuel cell 106 includes a proton generating electrode 204, a proton consuming electrode 208, and a membrane 206 between the proton generating electrode 204 and the proton consuming electrode 208. The combination of the proton generating electrode 204, the membrane 206, and the proton consuming electrode 208 together defines an MEA 209. In a fuel cell configuration, these components work together to convert the chemical energy from hydrogen and oxygen into electrical energy through an electrochemical reaction, which is consistent with... Figure 2A The electrolyzers in the two configurations are reversed. Figure 2A The electrolyzer configuration in the fuel cell uses electrical energy to split water into hydrogen and oxygen. In the fuel cell structure, the proton generation electrode 204 is where hydrogen (H2) is supplied and oxidized. Protons generated at the proton generation electrode 204 pass through the membrane 206 to the proton consumption electrode 208, while electrons are conducted away from the anode through an external circuit (not shown separately), thereby generating a current that can be used to power the load. In this configuration, the proton consumption electrode 208 is where oxygen (O2) is supplied and reduced. At the proton consumption electrode 208, protons (H2) that have passed through the PEM are... + ) and electrons that have already traveled through the external circuit (e - It also combines with oxygen molecules to form water (H2O).

[0060] Fuel cell 106 also includes GDL 218 and GDL 220. In some embodiments, GDL 218 is connected to inlet manifold 222 and outlet manifold 224 via flow channels (not shown separately), while GDL 220 is connected to inlet manifold 226 and outlet manifold 228 via flow channels (not shown separately). In a fuel cell configuration, inlet manifold 222 supplies fuel, typically hydrogen, to fuel cell 106, while outlet manifold 224 removes excess fuel from fuel cell 106. Conversely, inlet manifold 226 supplies oxygen (typically air) to fuel cell 106, while outlet manifold 228 removes water from fuel cell 106.

[0061] like Figure 2B As further shown in the text, in order to target Figure 2A A similar approach is discussed, where the proton-generating electrode 204 and the membrane 206 are modified relative to the proton-consuming electrode 208. In some embodiments, the edge 211 of the proton-consuming electrode 208 is recessed using the femtosecond laser ablation technique described herein. In this way, the potential gradient at the MEA 209 near the proton-consuming electrode 208 is controlled, preventing cation migration to inactive regions and improving electrochemical cell performance and lifetime.

[0062] Figures 3A-3D The sequential stages of a laser ablation technique are depicted for forming a catalyst-coated diffusion medium (CCDMm) with an attached film, having a modified proton-consuming electrode according to one or more embodiments. Figure 3A As shown, the laser ablation technology begins with the manufacture or sourcing of GDL 302 (note that GDL 302 can refer to...). Figure 2A and 2B The GDL 302 is not particularly limited and may include, for example, porous materials such as carbon fiber paper or cloth. In some embodiments, the GDL 302 is a diffusion medium (DM) electrode substrate.

[0063] exist Figure 3B In this process, a coated electrode 304 (catalyst layer) is formed on GDL 302, thereby defining a catalyst-coated diffusion medium (CCDM) 305. In some embodiments, CCDM 305 is H + Consumable electrodes (reference) Figure 2A and 2B (Proton-consuming electrode 208). While not intended to be particularly limiting, the catalyst can be applied to the GDL 302 in the form of a catalyst ink, which is a suspension of finely dispersed catalyst particles (such as platinum, platinum alloys, platinum-iridium alloys, platinum-ruthenium alloys, platinum-cobalt alloys, etc.) in a solvent. The catalyst ink may include a binder, such as polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polyvinyl alcohol (PVA), polyethylene oxide (PEO), polyacrylic acid (PAA), and / or carboxymethyl cellulose (CMC), which facilitates the adhesion of the catalyst particles to the DM and provides proton conductivity. In some embodiments, the catalyst ink can be prepared by mixing the catalyst particles, binder, and solvent to obtain a uniform and stable suspension.

[0064] exist Figure 3CIn this process, membrane 306 is laminated onto or directly coated onto CCDM 305, thereby defining a CCDM (CCDMm) 307 with the membrane attached. In some embodiments, membrane 306 is PEM (referencing...). Figure 2A and Figure 2B (membrane 206). While not intended to be particularly limiting, CCDMm 307 may include, for example, a proton exchange membrane (PEM), such as a proton exchange membrane made of a perfluorosulfonic acid polymer, but other proton conduction membranes, such as proton conduction membranes comprising polybenzimidazole and sulfonated aromatic polymers, are also within the scope of this disclosure.

[0065] exist Figure 3D In this process, electrode 304 is trimmed relative to GDL 302 and film 306. In some embodiments, electrode 304 is trimmed via laser ablation. In some embodiments, electrode 304 is trimmed via exposure to a femtosecond pulsed laser. In some embodiments, electrode 304 is trimmed via exposure to a CO2 laser. In some embodiments, electrode 304 is trimmed via the use of laser pulses. The laser technique used for trimming is not particularly limited and may include femtosecond lasers, CO2 lasers, or any other laser technique that can precisely remove excess catalyst layer material without causing thermal damage to CCDMm 307 (e.g., to the underlying diffusion medium and PEM).

[0066] In some embodiments, one or more laser beams 308 are positioned above CCDMm 307, and the focus of the laser beams 308 is set to correspond to a depth corresponding to GDL 302. In this way, the laser beams 308 can be used to remove (trim) portions of the electrode 304 without damaging the film 306 and / or GDL 302. In some embodiments, the electrode 304 is trimmed to a depth of 100 micrometers relative to the film 306 and / or GDL 302, but other trimming depths (such as 1 micrometer to 1000 micrometers) are also within the scope of this disclosure. In some embodiments, the electrode 304 is trimmed to a depth of 100 micrometers + / - manufacturing tolerances.

[0067] In some embodiments, during the laser ablation process, GDL 302, electrode 304, and film 306 are positioned above a vacuum plate 310 having port 312. In some embodiments, a vacuum 314 is applied to port 312 during the laser ablation process. Applying a vacuum to GDL 302, electrode 304, and film 306 during the laser ablation process ensures that catalyst ablation (e.g., platinum) does not re-deposit onto any layer of the assembly (e.g., to ensure that platinum ablation does not result in re-deposition onto any MPL, carbon fiber, or carbon paper substrate). In some embodiments, port 312 is positioned to guide vacuum 314 to draw gas inward away from the edge of electrode 304, thereby further mitigating the risk of re-deposition.

[0068] Figure 4A Depicting the relative to one or more embodiments Figure 3D The alternative laser ablation technique shown is the opposite of laser beam 308. Figure 4A The laser ablation technique includes two sets of lasers: a first laser 402 and a second laser 404. In this configuration, the first laser 402 and the second laser 404 are applied at different angles relative to the electrode 304. For example, in some embodiments, the first laser 402 is applied at an angle substantially orthogonal to the electrode 304 (e.g., 90 degrees), while the second laser 404 is applied to the electrode 304 at an angle between 5 and 80 degrees (e.g., 45 degrees). In some embodiments, the first laser 402 and the second laser 404 are configured such that the respective beams intersect at a sublayer portion (not separately indicated) (e.g., the portion to be ablated) of the target electrode 304.

[0069] Figure 4B Depicting according to one or more embodiments Figure 4A The top view of CCDMm 307 and vacuum plate 310 is shown. Figure 4B As shown, electrode 304 is trimmed (recessed) from both the first edge 406 (e.g., horizontal edge) and the second edge 408 (e.g., vertical edge) of membrane 306. In some embodiments, electrode 304 may be trimmed (recessed) relative to either or both of the first edge 406 and the second edge 408, as needed.

[0070] While the laser ablation techniques described herein primarily concern the three-layer MEA configuration obtained via the CCDM and CCDMm processes presented herein, other applications are also possible. For example, alternatively, roll-to-roll independent films can be laminated onto a CCDM to form a three-layer configuration, and the CCDM in such a system can be laser ablated to achieve the desired three-layer configuration. Figure 3D and / or Figure 4A The trimming is performed in a similar manner. In other embodiments, the laser ablation techniques described herein can be used to similarly trim unfolded film-coated gas diffusion electrode (GDE) assemblies and / or patch film GDE assemblies (not separately indicated). In some embodiments, the laser can be used to ablate layers less than 15 micrometers thick, trimming target electrode layers (e.g., proton-consuming electrode layers) without damaging the film layers near the corresponding edges.

[0071] Figure 5 Various aspects of embodiments of a computer system 500 capable of performing various aspects of the embodiments described herein are illustrated. In some embodiments, the computer system 500 may be manufactured, implemented, and / or otherwise incorporated into or combined with a fuel cell and / or electrolyzer system, such as fuel cell 106 and / or electrolyzer 118 (see reference). Figure 1 For example, in some embodiments, computer system 500 can control the laser to manage the laser ablation technique described herein for trimming proton-consuming electrode layers.

[0072] Computer system 500 includes at least one processing device 502, which typically includes one or more processors or processing units for performing various functions, such as any and / or all of the functions previously described herein. Components of computer system 500 also include system memory 504 and a bus 506 that connects various system components, including system memory 504, to processing device 502. System memory 504 may include various computer system readable media. Such media can be any available media accessible by processing device 502 and includes volatile and non-volatile media, as well as removable and non-removable media. For example, system memory 504 includes non-volatile memory 508 such as a hard disk drive and may also include volatile memory 510, such as random access memory (RAM) and / or cache memory. Computer system 500 may also include other removable / non-removable, volatile / non-volatile computer system storage media.

[0073] System memory 504 may include at least one program product having a set (e.g., at least one) of program modules configured to perform the functions of the embodiments described herein. For example, system memory 504 stores various program modules that typically perform the functions and / or methods of the embodiments described herein. One or more modules 512, 514 may be included to perform functions associated with any block diagram described herein. Computer system 500 is not limited thereto, as other modules may be included depending on the desired functionality of computer system 500. As used herein, the term "module" refers to processing circuitry that may include application-specific integrated circuits (ASICs), electronic circuitry, processor (shared, dedicated, or group) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide the described functions.

[0074] The processing device 502 can also be configured to communicate with one or more external devices 516, such as, for example, a keyboard, pointing devices, and / or any device that enables the processing device 502 to communicate with one or more other computing devices (e.g., a network interface card, a modem, etc.). Communication with various devices can occur via input / output (I / O) interfaces 518 and 520.

[0075] Processing device 502 can also communicate with one or more networks 522, such as a local area network (LAN), a general wide area network (WAN), a bus network, and / or a public network (e.g., the Internet), via network adapter 524. In some embodiments, network adapter 524 is or includes an optical network adapter for communication over an optical network. It should be understood that, although not shown, other hardware and / or software components may be used in conjunction with computer system 500. Examples include, but are not limited to, microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, and data archiving storage systems.

[0076] Now for reference Figure 6 A flowchart 600 for utilizing a membrane electrode assembly (MEA) with a modified proton-consuming electrode is generally shown according to an embodiment. Reference Figure 1-5 Describe flowchart 600, and flowchart 600 may include Figure 6 Additional steps not depicted. Although depicted in a specific order, Figure 6 The blocks depicted can be rearranged, subdivided, and / or combined.

[0077] At box 602, the method includes forming a proton-generating electrode.

[0078] At box 604, the method includes forming a proton-consuming electrode.

[0079] At block 606, the method includes forming a membrane located between the proton generating electrode and the proton consuming electrode.

[0080] At frame 608, the method includes forming a gas diffusion layer positioned in direct contact with the proton-consuming electrode.

[0081] At block 610, the method includes trimming a proton-consuming electrode relative to a first edge of the proton-generating electrode and a second edge of the proton-generating electrode. In some embodiments, the first edge and the second edge are orthogonal. In some embodiments, the proton-consuming electrode is trimmed at a focal depth bypassing the film using laser ablation.

[0082] In some embodiments, the proton-consuming cathode electrode is applied directly to the gas diffusion layer.

[0083] In some embodiments, the film is applied to the proton-consuming electrode by direct coating or lamination.

[0084] In some embodiments, the PEM electrochemical cell is an electrolyzer.

[0085] In some embodiments, the method includes forming a porous transport layer in direct contact with a proton-generating electrode.

[0086] In some embodiments, the porous delivery layer is connected to the inlet manifold and the outlet manifold via flow channels. The inlet manifold is configured to supply water to the electrolyzer. The outlet manifold is configured to remove oxygen and water from the electrolyzer.

[0087] In some embodiments, the gas diffusion layer includes a discharge manifold configured to remove hydrogen from the electrolyzer.

[0088] In some embodiments, the PEM electrochemical cell is a fuel cell.

[0089] In some embodiments, the method includes forming a second gas diffusion layer in direct contact with the proton generating electrode.

[0090] In some embodiments, a second gas diffusion layer is connected to an inlet manifold and an outlet manifold via flow channels. The inlet manifold is configured to supply hydrogen to the fuel cell. The outlet manifold is configured to remove water from the fuel cell.

[0091] In some embodiments, a gas diffusion layer is connected to an inlet manifold and an outlet manifold via flow channels. The inlet manifold is configured to supply oxygen to the fuel cell, and the outlet manifold is configured to remove water from the fuel cell.

[0092] Figure 7A A top view of a proton exchange membrane (PEM) electrochemical cell 700 according to one or more embodiments is depicted. Figure 7B A cross-sectional view of a PEM electrochemical cell 700 according to one or more embodiments is depicted. The PEM electrochemical cell 700 can be configured as a PEM electrolyzer as needed (see reference). Figure 2A Electrolyzer 118), PEM fuel cell (reference) Figure 2B (The fuel cell 106) or any other PEM battery.

[0093] As shown in Figure 7, the PEM electrochemical cell 700 includes multiple manifolds 702. It should be understood that the number of manifolds (inlets and / or outlets) shown is merely illustrative and not particularly limiting. The PEM electrochemical cell 700 may include any number of manifolds 702, and all such configurations are within the scope of this disclosure. The manifolds 702 may include inlet manifolds and / or exhaust manifolds employing any of the configurations previously described. The manifolds 702 are arranged within a frame 704 (also referred to as sub-gaskets) of the PEM electrochemical cell 700. GDL 302 is arranged between the heads 702 in frame 704.

[0094] As further shown in Figure 7, the PEM electrochemical cell 700 includes an active region 708 isolated from the GDL 302. The active region 708 may be connected to the manifold 702 and the GDL 302 via a flow channel (not separately indicated). The active region 708 refers to the region in the PEM electrochemical cell 700 where the main electrochemical reaction occurs. In some embodiments, the active region 708 is formed by the overlap of the proton exchange membrane (PEM) (e.g., membrane 306), catalyst layer (e.g., electrode 304), and gas diffusion layer (GDL) (e.g., GDL 302) of the proton exchange membrane (PEM) electrochemical cell 700 (see Figure 7). Figure 7B The active region 708 is defined in some embodiments by an opening 710 within the interior of the frame 704. In some embodiments, the GDL 302, PTL 202, and membrane 306 overlap the frame 704 (sub-pad) at the opening 710 (i.e., these layers may extend below a portion of the frame 704 beyond the opening 710 of the active region 708, as shown). Figure 7B (As shown).

[0095] While not intended to be particularly limiting, frame 704 may include an elastomeric membrane and / or polymer layer for protecting the edges of the PEM (not shown separately) from damage and degradation. For example, in some embodiments, frame 704 may include materials such as polyethylene naphthalate (PEN), polyimide (PI), polyethylene terephthalate (PET), or polyphenylene sulfide (PPS) membranes. Furthermore, frame 704 serves as a seal to prevent fluid leakage through components within frame 704 to areas such as active region 708. In some embodiments, frame 704 provides mechanical support and / or stability to the PEM and helps control the overall thickness and uniformity of active region 708.

[0096] The term “a” does not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, the reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0097] Furthermore, as used in this disclosure, phrases such as "at least one of A, B, or C" or "at least one of A, B, and C" should be interpreted as selecting at least one from the group including "A, B, and C". Unless explicitly stated otherwise in conjunction with specific examples in this disclosure, this phrasing does not imply "at least one of A, at least one of B, and at least one of C". As used in this disclosure, the example "at least one of A, B, or C" would cover any of the following selections: {A}, {B}, {C}, {A,B}, {A,C}, {B,C}, and {A,B,C}.

[0098] When a component, such as a layer, film, region, or substrate, is referred to as being “on” another component, it can be directly on the other component, or there may be intermediate components. Conversely, when a component is referred to as being “directly” on another component, there are no intermediate components.

[0099] Unless otherwise specified herein, all test standards are the most recent standards in effect up to the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which a test standard appears.

[0100] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0101] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, this disclosure is intended to be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A proton exchange membrane electrochemical cell, i.e., a PEM electrochemical cell, comprising: A proton-generating electrode, which includes an anode; A proton-consuming electrode, which includes a cathode; A membrane located between the proton generating electrode and the proton consuming electrode, wherein the proton generating electrode, the proton consuming electrode, and the membrane together define a membrane electrode assembly; and A gas diffusion layer is positioned to be in direct contact with the proton-consuming electrode; The proton-consuming electrode is trimmed relative to a first edge of the proton-generating electrode and a second edge of the proton-generating electrode, the first edge and the second edge being orthogonal, and the proton-consuming electrode is trimmed at a focal depth bypassing the film using laser ablation.

2. The PEM electrochemical cell according to claim 1, wherein the proton-consuming cathode electrode is directly applied to the gas diffusion layer.

3. The PEM electrochemical cell according to claim 1, wherein the membrane is applied to the proton-consuming electrode by direct coating or lamination.

4. The PEM electrochemical cell according to claim 1, wherein the PEM electrochemical cell includes an electrolyzer.

5. The PEM electrochemical cell according to claim 4 further includes a porous transport layer in direct contact with the proton generating electrode.

6. The PEM electrochemical cell according to claim 1, wherein the PEM electrochemical cell comprises a fuel cell.

7. The PEM electrochemical cell according to claim 6 further includes a second gas diffusion layer in direct contact with the proton generating electrode.

8. A vehicle comprising: Electric motor; A battery, which is electrically connected to the motor; and A proton exchange membrane electrochemical cell, i.e., a PEM electrochemical cell, electrically connected to at least one of the electric motor or the battery, comprising: A proton-generating electrode, comprising the anode of the PEM electrochemical cell; A proton-consuming electrode, which includes the cathode of the PEM electrochemical cell; A membrane is located between the proton generating electrode and the proton consuming electrode, the proton generating electrode, the proton consuming electrode, and the membrane together defining a membrane electrode assembly; and A gas diffusion layer is positioned to be in direct contact with the proton-consuming electrode; The proton-consuming electrode is trimmed relative to a first edge of the proton-generating electrode and a second edge of the proton-generating electrode, the first edge and the second edge being orthogonal, and the proton-consuming electrode is trimmed at a focal depth bypassing the film using laser ablation.

9. The vehicle of claim 8, wherein the proton-consuming cathode electrode is applied directly to the gas diffusion layer.

10. The vehicle of claim 8, wherein the membrane is applied to the proton-consuming electrode by direct coating or lamination.

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